I think it’s looking pretty good! I’ve been trying to think up a way that you could jury rig a drill to hold the threaded piece - perhaps a threaded bolt and an expanding piece of rubber to grip the inside of the piece. Then you could fix your drill to your workbench, make sure the piece is square and use a file to smooth it down to roundness.
It wouldn’t work for large pieces, but should work in theory for taking off small amounts of material from something like this. Just an idea 
Rubber Stoppers, are available in different sizes.
Wow, that’s some serious patience.
More photos and info in the first post.
Where is everybody? You would think that this is some kind of holiday week-end or something! 
Do people get off on holidays? I'm working tomorrow. I work every holiday.
Nice work OL. Great way to join the two parts. Holds strong. And it will be a sweet light for sure since it can still be adjusted.
You make great things from small objects sir!
I'm hear as usual, watching with interest, but very quietly.
I'm still here trying to convince myself I don't need another SST-90 light. :P
battery holder is finished, see first post.
I’m not sure I like all the “teasing”…maybe it would be better on us if you post it all at once! 
Good stuff, as usual, O.L.
Well you're probably right.........
So I won't show the SST-90 on the Copper Star.
Yes, it looks funky, but it does work. There's two 7/8" 18ga copper disks, with a chunk of copper sitting on top. The wires are soldered from underneath and all the AA is because I don't like the wires suspended that way, so I wanted to make sure they were supported well. I could see one of the terminal strips peeling right off, now they won't. The led is soldered to the block, the block is soldered to the discs, which are soldered together. This will go on top of an aluminum heat sink that's the diameter of the mag tube and about 1" thick. That ought to keep things cool for a few minutes, but probably not longer. I am shooting for about 9.5 amps with it.
I tried it on 3AA eneloops direct and it is definitely about twice as bright as an XM-L. It will be interesting to see over 9 amps hooked up to it with 12 eneloops.
My apologies for the tease, but I just can't help myself.
Great work as usual Old L. That is a serious amount of work.
Sweet idea with that heat sink. Good job. I admire how fast you work despite taking care of the house and the missus and negotiating the heat too. Wish I had some of that tenacity O-L.
You are such an inspiration! Love that batteryholder.
Ive used 2x4 and 2x3 AA Eneloop for SST90 but it never got me real 9A. 3x3 should do better.
Justin, wonder where you got the SST90? I wish I had the $ and time to play with it like you do. Right now I’m just learning and hoping to “play” with all the knowledge you and others provide some day.
This is how the light will look. I don't plan on a lot of embellishments. The only other thing I have to do to the body is the 550P treatment. I think it will look good with a Pa____rd w__p.
I'm waiting now for an Aluminum Heat sink. If I'm lucky, I might get the led/sink/drivers ready for testing this week end. Then I have to check focus distance and put the lens in permanently. After that it's the final touches, so by the end of next week, I might be able to do beam shots. I will do them at work, but I have to to do them on the week end, when I'm off. I have about 6 targets to use, from 300 yards, to 1.2 miles. No, I don't believe it will go that far, but that's a good target. It's a high rise on a hill and I'm on a hill at work.
Serious shower power. Great thread.
Aw man! This rocks!
Great stuff so far, O-L! Really like what you did with the host. Looking forward to you wrapping it up and turning it on. 8)
More photos, including a wiring diagram, in the first post.