Re-machining an E series SF bezel, how is it done?

[MacTech]

I have a spare E series head/bezel that i'd like to try my hand at modding

the only tools that i have available to me are drills, and a Black and Decker Dremel-clone, i have no access to a lathe or other sophisticated machining equipment, and even more importantly, no skill to speak of

my plan is basically to find a way to cut off/drill out the "neck" of an E series head (older non-crenalated bezel) to allow me to insert the light engine "pill" of my old G&P 3W Luxeon upgrade (P60 style)

the potential flaws in this plan that i can see are;

the reflector of an E-series head appears to be part of the actual head itself, there does not appear to be a seperate removable reflector, so simply drilling out the neck (even if done slowly) is risky, there is potential to damage the aluminized reflector, however, given the cramped quarters inside the head, it also appears that cutting the neck off would be problematic without specialized tools

so, given my tool arsenal of a drill and a "Dremel", what are my options in re-machining the head, or do i even have any

Hmm, as i've been thinking about this, i may have come upon a solution....

i believe there are Dremel bits that are essentially a half-sphere of grinding material with the mandrel shaft sticking out of them (think of a round lolipop with the bottom half cut off)

if i keep the cutting RPM's low and use a cutting fluid (water? 91% Isopropyl alcohol?) i should be able to minimize damage to the reflector, and slowly grind down the neck.....

 

[kromeke]

I be reluctant to use water or anything flammable near a Dremel. The brushes arc and fluids can get into the inside. Now if it is a drive shaft style, maybe. Don't go getting electrocuted now.

To answer you other questions: it is all dependent on your skills as to how this can turn out. I've seen some work with skilled craftsmen using minimal tools, but if you aren't experienced with this sort of work, you might be disappointed with the results. Are you willing to risk ruining parts? If you willing to accept some losses, you can learn to work with what you have. Cutting alumium neatly with a Dremel is difficult. But I don't want to discourage anyone, just pointing out the risks.

 

[MacTech]

Kromeke, this is a spare head i'd be using, i have a new E series head that i can keep using as an incan head should this project fail, i'm not expecting it to go smoothly, but i can hope for the best

i've accepted the fact that i'm probably going to screw *something* up in the process, so no biggie if it doesn't work out

here's what i envision happening;

Step 1; use some form of heat (electric stove on high, heat gun, blowtorch, microwave oven (just kidding on the last one) ) to heat up the bezel ring and remove the glass window and bezel using leather gloves and/or strap wrenches

step 2; once the window and bezel are off, block off the reflector with masking tape or electical tape or something

step 3; put head in large steel vise to prevent unwanted movement, ideally facing reflector-up or at least at a 45 degree angle, to allow aluminum shavings to drop clear

step 4; attach grinding head to B&D RTX rotary tool, set on "Low" (12,000 RPM, as low as it goes)

Step 5; slowly grind away neck inside the head, stopping frequently to check progress

Step 6; once neck is gone, grind away the threads on the Luxeon "Pill" (the pill *almost* fits in the head anyway, goes in about a half a turn before it's stopped by friction) and drop it into the head to check fit, adjust the pill as needed

step 7; clean up the reflector, reattach bezel and window, drop in pill, fire it up and admire a succesful mod...