Replaced optics in SP40 - mistakes were made

Changing the reflector rarely goes smoothly because, as you found, in a light like this the reflector heights have to be very close for everything to fit right. You pretty much got it to fit though, so nice job. Another thing you could try is to use DC fix diffusing film and keep the stock reflector. You just put the film on the glass lens. See here.

Also regarding the tint of the LED, when you dedome the color temperature gets warmer so that probably explains how warm it is.