Well, CM, the macho modder side of me is threatened by your remarks! /ubbthreads/images/graemlins/ooo.gif /ubbthreads/images/graemlins/yellowlaugh.gif
Actually, I almost expect you to come up with elegant solutions to stuff like this. I don't even have the equipment to remove copper from the head in anything remotely resmbling a professional manner. Great job on your research! And sorry you had a few casualties in the process. /ubbthreads/images/graemlins/wink.gif
As for me, I can report that I've successfully modded my first FF II head, but did it in a completely different manner. At first I tried to make the reflector look like the optic, complete with the flange along the top. It worked but had some bubbling that wasn't aesthetically pleasing, and my CPF "client" suggested that given the premium nature of his FF II, he'd prefer a more sexy look to the reflector. So attempt #1 went into the scrap bin. /ubbthreads/images/graemlins/icon15.gif
Reflector #2 was a long, slow, deliberate process. One secret, folks: a Dremel bit that CUTS won't heat up the plastic even remotely as much as a grinding or sanding bit will! In fact, one of my favorite misuses of a bit is to use a burring bit intended for cutting ceramic tile, and using it to chip the reflector down to size, chip by chip. Works great, and if you're careful it doesn't heat the plastic to any significant degree. /ubbthreads/images/graemlins/thumbsup.gif
Unfortunately, the bubbled reflective surface isn't just a product of heat, but also of grinding so deeply into the reflector that there simply isn't enough plastic backing to support the reflective surface. So after all my patience, the top end of the reflector still started to buckle. /ubbthreads/images/graemlins/frown.gif
Finally I chopped the top off the reflector completely, as suggested by someone above, and made a friction fit of the reflector into the head. Then I fitted an O-ring into the open copper gap above the reflector, and another, larger O-ring where the flange would have been to support the lens. The result was a kinda cool looking head, with two overlapped O-rings (looks a little exotic somehow) and a nice, clean reflector below. The beam projects a beautiful round hotspot surrounded by bright sidespill.
Success! /ubbthreads/images/graemlins/party.gif
Now as far as taking on this work for others, let me say that this mod was a royal pain. /ubbthreads/images/graemlins/mad.gif I'm willing to do the work, I guess, but any potential customers should be aware of my three ground rules on this...
1. I'm gonna charge $30. Seems a little high, but it takes a lot of time to get the thing right, and I just can't afford to spend that kind of time on a bazillion reflector mods.
2. You'll need to send me your entire light so I can make sure the fit is correct.
3. There's no guarantee that the reflector will end up perfect, although I will of course do my best.
Sorry if that discourages folks, but I really felt burnt out after doing this first reflector. Happy to help, though, for those who need it.