Re: need help with custom reflector
Why on earth would you want a 3200 lumen dive light? Unless you dive in crystal clear water you'll just end up getting blinded by backscatter.
Maybe he dives in mud or just wants to do a lot of video work. Besides 35W-50W HID dive lights are very common so I don't think his idea is odd.
Utahdeepdiver, I'm not an optical engineer so I won't be able to answer your question. Typically designing then finding a company who makes reflectors to your specifications would be a costly and timely process. If you were going to undertake something like this you'd want to start with reflector cad software at ground level.
It would be much easier and less expensive to just start with a pre-existing reflector. Even a high quality electroformed reflector would cost less than the developement of a new one.
http://www.optiforms.com/3000products/31500efASSEMBLIES.html
If I was going to do this, I'd research about which bulb I was going to use then call Optiforms or another manufacturer to see what's avaiable to work with it.