First off, big thanks, great job, these work exactly as I imagined.
For clarity I'll call the dimensions ID1, ID2, OD, Thickness, Step Height.
ID1 should be 0.98 (was 0.96) it's strictly a clearance so as long as it's not smaller than 0.96000, you're ok. (After a light sand sample ring #1 fit perfectly)
ID2 unchanged at 1.26 - All four sample rings were a good fit. This is a reference dimension and controls bulb position in the adapter side-side.
OD unchanged at 1.69 - all four sample rings were a good fit. This is a reference diameter and controls adapter position in the THOR reflector side-side.
Thickness is unchanged at 0.335" - all four samples were fine. This is NOT a critical dimension, though if too short, the collar for ID2 will not function well.
Step Height should be 0.26" (was 0.235) This is a critical dimension and controls in-out focus of the bulb. A perfect focus would actually be just a hair taller, but due to anticipated variation in reflectors, bulbs, and adapters, I think 0.26 should be the target since it's easier to shim a layer of tape than sand down the same amount. Note that I could not see any difference in the focus on the four sample rings.
I've finished my THOR HID Mod, with the adapter ring, it's trivial to throw a few zip ties on the bulb to hold it VERY securely to the reflector.
p.s. P.L.M.K. if you want me to send these sample rings back, otherwise they can be the four I wanted.
p.p.s. My email to you bounced, looks like yer mailbox is full. I'll post some pictures here tonight.