Purchased some aluminum from my local Metal Supermarkets. Got a discount because these were leftovers from cuts for other customers. They don't just give a discount. I had to point out that they would not have to cut up any new stock and that I would take the whole of the two remaining pieces below (I have cut out some disks from it in the below picture). The plate is 1/4" 6061 aluminum. The tube is 2" (5.1cm) OD and 1/8" (3.2mm) wall thickness and type 6063 alloy. I really wanted matching materials to help have more consistent results with anodizing, but cost would be too high that way.
Got the reflector I wanted and scored some 1 1/2"ID (38mm) used copper pipe from a landscaper on Craig's List. Wall thickness is .07" (1.8mm).
Reflector:
I didn't want to reveal the reflector until I could show it in action with a couple of ideas I have, but time is running out. The reflector is the CST90 from Illumination Machines. Those folks make amazing products. I tried to get a group buy together one time for this reflector, but got no traction.
This reflector is a defect, has some dents and some dull spots from sanding/cleaning or something. It was the best I could get from IM as I could not commit to buying a minimum 100 units. I have played with this reflector by hand and can tell you it is an impressive thrower. I got close to 300kcd with a dedomed MT-G2 driving around 11 amps. I have some interesting emitter plans, but I need the basic light completed to try them out.
Nuts and bolts that will hold almost everything together:
