So, you have a XPG/XPG2 you want to use in a XML/XML2 reflector, but the locating/centering ring on the insulators are different sizes, and it's a pain to keep all the parts aligned while screwing it together. I wish somebody made these for sale, but they don't, so we have to make them ourselves. It's easy.
A XPG has a 3.5x3.5mm square base (okay, actually 3.45x3.45, close enough), and corner to corner it's about 5mm, same size as the raised round locating ring on the XPG insulator.
And the XML is 5x5mm, and 7mm corner to corner, which is the size of the round ring on the XML insulator (and the hole size of a XML reflector).
The round raised part of the XPG insulator fits exactly inside the square hole of the XML insulator, like so:
That's a XML insulator stacked on top of a XPG insulator. If your reflector has the best focus with that thickness all you have to do is cut down the XML insulator to a round shape, or glue them together, and you're done.
If you need a thinner, single thickness insulator, that's easy too.
Cut right up against the raised ring and it'll come out the right size with no filing or fitting (which is the stage of building stuff where I end up destroying the most parts, so best to just avoid it altogether if possible). And due to the shape of the edge on the blade, the cuts will be slightly tapered, wider at the bottom than at the top. That keeps them locked together once the reflector is pressing down on the XML part of the assembly - the XPG part in the center is held down by that taper. Insert the little square XPG adapter from the bottom.
Bad contrast, but I think you can see it well enough to figure out how it works.
Once they're pressed together and flush on the underside, file or sand off any of the XPG part that sticks up higher than the raised ring on the XML part, if like with my example parts here the XML insulator is thinner than the XPG part was.
Done! :p
