pretty much have to just ease the reflector out and let the legs bend an/or break. just be careful to keep the shiny side pristine.
I had called terralux and got the Ok to put the full li ion voltage thru there mirco, just heat, no real damage to the module. I resistored it down once but since the interaction between the SMD and the reflector makes for poor throw
I went back to having full juice, i just don't use it very long, much my other 1xAAA type KC light's.
I recommend drilling rather then sanding the reflector too, this will give you a little more material left, and give the switch more to bite on then sanded down.
There are some tricks i have been doing to soli reflectors since i started moding them last yr. the last 2mm is flat on it, and if your very careful it can be removed from the main portion and fused with a stock (but drilled) one
for a uber flood and power. (I 'm given' all my soli secrets away so don't any of you's go makin' and sellin' these on the custom BST! just kiddin
)
One more thing, the reason the soli is giving out so much flood vs hotspot is the nature of the SMD/reflector interaction. the micro throws like hell in a 2xAAA mag because of the strong parbolic curve were the SMD's very low mounting starts on the terralux made reflector. I wish these could be ordered in a regular 5mm or even lux,
Because when placed in the reflectors hot spot, the 5mm do throw!
I got two soli conversions with 35K 5's "Resistored" that make a new ARC v4 look like stock soli.
Anyway my point being, I don't think much can be done on the soli reflector for throw, at 3.7V maybe someone with better skills can suss out the current/voltage requirements of the micro and find a replacement LED that would spank bigtime. I truly love the terralux modules and the micro for a soli mod,, just feel it could use a better LED. VDG