While standing at the belt sander, I kept thinking, “I wish I was friends with a machinist.”
gchart, I removed most of the metal using a belt sander with a 40-grit belt, and it’s slow going. I moved the bezel side-to-side across the belt, and regularly rotated it to prevent uneven wear.
I love this quote by ‘old4570’ I found in this thread while reading about grinding/filing/sanding stainless bezels:
I surprised myself by managing to keep all three Q8 bezels very flat and even. I left them installed while working so the light could act as a handle and heatsink.
What lights are you thinking of altering? Perhaps you could start with an easily-replaceable (and available) bezel in case it doesn’t work out.