When clearing out my son in laws house I found an old hand held spotlight similar to the one in the photo. As you will see I removed the reflector .trimmed the edges with an angle grinder and glued it over the original reflector with silicone ..EPLS




We gone


Sharp edges .clean with dremel


Looks perfect to me

 

I have to wonder what your light output is now like. The flashlight's reflector is not designed with the same optics as the high beam reflector. You may have scattered light output now.

 

Who cares as long as it passes the MOT there is no pattern specified for a main beam it only has to be efficient

 

Agreed, it certainly can't be any worse than that corroded flaking reflector you covered.

I guess you could just go to a junkyard and pick any appropriately sized reflector off any car and do the same thing.