ElectroLumens,
I haven't tried a SE star as I don't buy stars; prefer the bare emitter. However, I do have a couple low dome cyan stars with the cool, "true" cyan color so I did try one of these in an Ex head. I made a .750" mask out of 3/4' Al bar stock with a hole drilled in the center to accept the LED. I held the star inverted into this mask and then ground off the portion of the sink base that extended past the perimiter of the 3/4" Al mask. The star drops down into the Ex head nicely. I also turned a counter bore into the back side of the Ex so that the star seats on a lip in the head and the soldered contacts don't make contact with the head. Unfortunately, the low dome doesn't work in the Ex head. Had the LED been a SE or HD, the result would have been good. When the surface of the star's base is in contact with the existing reflector bulkhead in the Exe head, you have an excellent focal allignment. I think you can also cut the LED leads right at the LED and then bring up wire leads through the MPCB and solder direct to the emitter. This would render the contact points and circuit on the board disconnected.
- Don
EDIT: NOTE, you still need to drill out the existing LA pedestal with a 13/32" drill bit to allow for the LED and soldered connections to pass through the reflector.