**Hi all 
I was planning a scratch build for a 86mm reflector and Luminus 90.2 but was unsuccessful finding a driver.
Thinking maybe a flashlight can be modded to accommodate my plan, the search led me to this Convoy 4x18.
Now it was a guess if it would work and after receiving everything, measuring, drawing it on Cad, it will fit, surprisingly. :sunglasses:
This will take some time, so posting pics as it progresses, just for fun.
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It is hard to see but the led is tilted and off center causing a terrible beam.
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I cannot get a good pic but you can slightly see it here. There is no round hot spot and further away is worse.
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Here is the 86mm reflector for comparison.
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New reflector with bezel.
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Head modded for heat sink.
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Reflector modded finished.
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Heat sink.
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Here are the before and after numbers.
Note: lumen tube numbers are elevated slightly from inaccuracy of my lumen tube.
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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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Here are the dims for the reflector if someone wants to do this mod. It is not too hard to do on a manual lathe like I did.
The threads in metric are 64mm x 1.0mm or 2.519 x 25.4 tpi ( I used 26 tpi on my lathe ).
Turn the diameter to 64mm ( 2.519 ) and 37.4mm ( 1.472 ) from the small end of the reflector.
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You can buy the reflector HERE
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You can get the 86.3mm lens HERE
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Here are the dims for the bezel, no threads.
PM me for help with the bezel, mounting it was tricky, but not complicated. 
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How can you fit a bigger reflector in the same host? The one you have pictured looks way too big.
Good question. 
Clue’s in the OP’s name. Sit back and watch
Oh...
Duh! 
Well, he is gonna have to “CNC” the host. This should be interesting.
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Yep, everything is going on the operating table. We need more entertainment here at BLF, thought this would be fun to see.
It is going to fit, and look good. I hope. :sunglasses:
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How much do you get to pay for this level of quality—it’s priceless i’m sure.
Go getcha one of those $1 budget beater lights with a round emitter, you will love the beam compared to that one.
Budget Beater
Super intrested with qhat you come up withw
OK, it’s time to get started this week machining the head, reflector, and copper heat sinks. Here are some tear down pics prior to machining.
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Also did some inspecting of the problem with the led offset and was able to find the problem. The mcpcb’s are never flat on any flashlight that I have checked and this one is exceptionally warped from the stamping process. It was tilted badly because one screw was tightened and the second was less tight to prevent bending and de-soldering the led from the mcpcb. The correct way to fix this ( every mcpcb ) is to use fine sand paper on a flat surface and carefully sand flat the bottom of the mcpcb.
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Purchased this computer/phone disassembly kit from Walmart for $15.00.
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Another problem with the Convoy is the switch leds do not come on ever.
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The driver looks to be wired for the switch leds. I will look into this problem soon.
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I LOVE when you have new projects CNCman, looking forward to this one VERY MUCH, glad folks with talents like yours (and others) keep this forum fun and interesting on what is possible. Maybe my wife will Let me buy that 5-axis CNC machine, next year :)) but then I would need to learn how to use it haha
can't wait for your updates!
Oh oh, my guess, cncman is going to machine a "head extension", that threads into the bezel threads and opens up wider to accept the larger reflector?
am I close?
I couldn't imagine you will machine a whole new head, at that point you would be making a New flashlight lol.
I’m going to thread the reflector directly to the head, no adapter this time, no room for it.
Strangely enough it will fit, unless it unexpectedly cuts thru the reflector. LOL
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Next it needs some copper heat sinking because it gets too hot too quickly.
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After that it needs a new bezel to hold the lens in place.
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Here is the free 2D CAD i have used for years, easy to learn.
FREE 2D CAD
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Thanks for the nice comments 
It is fun to make things and share that with you guys
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That is an excessive amount of thermal paste between the shelf and the MCPCB. Interesting that the MCPCB was that warped and the screws were only tightened to a certain point due to the LED.
I always sand the bottom of my boards with fine sandpaper on a small mirror to get them very flat. It seems for the most part they are flat, but there are usually spots on the edge or by the holes that show signs of being sanded first before the rest of the board.
Looking forward to your mod CNCman!
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.