shouldn't be any damage unless you try to clean the damn thing. *anything* will scratch the reflectors
basically any ls mod you do will require reflector trimming. it still works quite well in origional mode after modified (although why you would want to go back is beyond me...)
those instructions are a little old, any heatsink you buy from him will be automatically fitted to the right size, so you won't need to mod the heatsink.
a hint: when drilling the holes for the wires...make them as far apart as possible. once i was careless and drilled them too close together, and the emitter wouldn't fit
also, i stead of using the bulb, use a wooden dowel that will fit inside the hole where the bulb goes, and trim off all the black stuff around the bulb-hole so the luxeon can go further into the light. don't worry about being un-even or anything, just break that black crap off.
and when usinging the dowel method, after trimming that black crap off from around the bulb hole, push the bulb=socket down as far as it will go (the socket is the metal hole that was inside the black plastic hole) and push it down as far as it will go, then take that brass strip and bend it over the metal-bulb hole to hold it down.
take the brass strip that is holding the metal bulb-hole down, and slip your negative wire underneath it (make it at least 6 inches long, you can trim afterwards) after you have the negative wire soldered around the brass strip, you can insert the wooden dowel/bulb that you made.
also, don't bother sanding off the paint inside the body of the flashlight...this won't really improve thermal transfer, and is a pain in the butt, will probably make the thermal transductance worse due to the larger gap between the heatsink and the body.
anyway, after doing the body modding, attach the emitter between the two wire-holes as shown in lambda's instructions. after letting the emitter set undisturbed for at least 40 minutes, take the emitterized heatsink and apply artic silver to the outside of the sink, (or the inside of the *ag body) then poke the wires through in their corresponding holes (negative wire goes to the ls lead that does
not have a hole), and shove the heatsink down as far as it will go, while pulling both wires to assure they don't get cramed down into the body and broken. then but them to the appropriate size, and solder them on.
easy huh?
you'll notice that i didn't expain everthing, just elaborate on some things lambda may not have mentioned.
if you search in the "homade and modifed lights" for "cyclops instructions" or something like that, you will find better instructions, and i have some pictures in there that might be helpful, and the way it did the dowel/bulb works better than any other way i have found.