I have an early "prototype" red and amber star (alas, no optics) I should try in that 2D RayOVac Industrial. I didn't think a TO-220 sink , or even two, would be enough for the luxeon.
I bought one of the lights at Home Depot for about $6 because it looked comfortable (it is) and it has a battery indicator. The indicator works much better than the one on the Craftsman/Sears rubber 4D lantern. Yellow's on at about 2.2V.
Not sure how I'd get the LED in at just the right depth, or how I might attach a heatsink with a screw since I have only regular epoxy, but you're right, the reflector is not the usual plastic. For one thing, the bulb butts right up on it so it must be fairly heat resistant.
Do you attach the star to the reflector or the plastic struts in the head? If the former, how do you deal with the screw-on part twisting the wires?