MAG-Lite AA Reflector

[UVLaser]

How can I shape a reflector to be the same size as a MAG-Lite AA reflector?

 

[smokinbasser]

Lost wax casting using a coke can as the metal source, sorry,engineering flashback. Seriously I think to match it you are going to need a mold made as a template.Why? I am assuming your talking about metal as opposed to plastic. Something getting a mite warm? Plastic is relatively easy to shape. Start with the closest match in dimensions and cut it to spec and have it remetallized via a vacuum process.