Finished the SS Bezel today. Next up the head prep for heat sink.
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WOW! it looks awesome! you are a true craftsman, sir!
I got some ideas i need fabricated :)
This is looking good! I’m excited to see how it turns out. I’ve wanted to put a 86mm key reflector in an L2 for a while. I don’t have your skills though!
Just finished mating the reflector to the head.
Heat sink is up next.
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Amazing work.
It has been a busy week with no time to finish the heat sink. So here are some CAD dwgs I drew up before starting to verify fit before machining anything. The head threads are 64mm x 1mm 60deg. This was a total guess before purchase if the Convoy would fit directly to the 86mm reflector. Drawing dimensions were accurately drawn.
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The green in the middle is the MCPCB and LED.
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Amazing mod....LODI....Hope it can also fit to Convoy L7
Finished the heat sink. It was a tight fit after hand polishing it to go in with a running slip fit @ .0015 or .0381 mm clearance on both diameters for best contact with a little Arctic MX4 thermal compound added.
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This part was challenging to design and make. Calculating position and size on the 2D CAD made this possible. I highly recommend anyone wanting to learn CAD to get the 2D FREE version. HERE .
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I will do some measurements today for lumens and throw.
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Compaired to the MT07 Buffalo with the same reflector.
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Beam shots not great but very bright downstream.
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You are great !!! It is beautiful and certainly very performing, congratulations on your work, it's been a while since here on BLF I haven't seen such a well done customization. Truly a really beautiful job.
You should sell this modification in a kit ... I would be the first to buy it, it is so well done that it looks like a production production and not a customization.
WOW! just checking the thread again and you're done! AWESOME work cncman! It looks really good too, which i know you must have considered, but sometimes its all about the performance, i agree with Fedtro that this looks like it could be a production run!
I know for one, i would definitely buy this "kit" if it were ever made. only thing is it would cost more than the original light with the cost of just the machining hours and design. either way, nice work, so glad to be able to see it happen!
Congratulations, CNCman. This is amazing skill and imaginative.
I especially like the large SS bezel. You could sell this design to Convoy! I believe many of us BLFers would love to buy one if Convoy makes this from your design for sale. 
Thank You, Fedtro and ArtieT59 and TermsakC for the kind comments 
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It is fun mixing things up, to help everyone think outside the box and enjoy this hobby.
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In 5 yrs hoping to retire and get a small CNC Router, maybe scratch build it to get the rigidity needed to thread mill and a 4th axis to do designs on battery tubes. At that time the door will open to do more things for everyone, and I am looking forward to doing this and not for profit. Right now, time on the machine and availability is very limited. 
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As for selling design to convoy, I never thought anyone wanted it, they are welcome to copy it, but for a production run it will work without the heat sink and the reflector uses a light thread locker for security.
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Great mod! Fitment and finish looks like it came from the factory
Very impressive. Now, if someone would make a light just like this but twist zoomie, I could probably be all set for a long time lol
Thanks everyone 
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Here are the before and after numbers.
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Stock:
Lumens: 4800
Throw: 1004 meter
CD: 252392
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Modded:
Lumens: 5400
Throw: 1742 meter
CD: 758680
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The end result was very good. It runs much cooler and longer. The beam downstream was no comparison.
No mod to driver or batteries, the only difference was the reflector and heat sink.
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A deeper reflector does make a difference in throw. It throws better than the Buffalo with the same reflector at 1192 meter using a Lexel driver at 12v 6a and a XHP 70.2 with 9000 lumens. Proof as stated at Aliexpress that it was made for a SBT 90 led.
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Amazing work! I rather like the look as well.
How many hours do you reckon you put into this, total?
Great job CNCman!
That is 1 heck of a copper heatsink for the MCPCB! And the fitment is superb.
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Thank You :sunglasses: I’m guessing 5 hrs CAD for measuring and getting dimensions and 2 hrs machining.
Planning and research looking for a host for the reflector took months off and on.
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Very well done!!!