Thanks for the info guys, this could be interesting...
I am aware that an XP-G is going to give a relatively unfocussed beam compared to an XP-E or an XP-C, I suppose I should explain what I'm doing here.
I'm taking a swing at using a reflector + aspheric combo as described by Saabluster
here. Note that this is different to the usual combination where both elements are rather large, with a horrible result. The reason this result doesn't look horrible is because the light captured by the reflector is sent mainly through the centre of the aspheric, where it's only refracted by a small amount and not sent off in some greatly off-axis angle, as usually happens with a reflector + aspheric combo.
From what I can see the McR-12 and -8 fulfils the first of his criteria quite well, and the third is simply a matter of turning down the reflector to fit. Only query now is how much I have to adjust the reflector height to get it to focus.
On the other hand, if anyone knows of any reflectors that fill these criteria but are also smooth (about the only element I can think of that would improve on the McRs for this application), I'd definitely like to hear about it.
Edit: Why use an XP-G in the first place? It seems to me that the XR-E isn't getting much in the way of improvements from Cree, but the XP-G certainly is. Hence when better binned XP-Gs come out, I can simply swap them instead of having to rework things, as I would if I were using the XR-E.