My wifi is back so here's the headlight snafu and rebuild...
First I was drilling the back of the bulb out for bigger LEDs I got out of these lanterns...
well I broke the bulb, so I started scavenging...
and found the aluminum sheet and cut 2 holes out "old school"
I cut the reflectors down to fit two across and glued them in with ShoeGoo, which is a nice thick silicone.
fits in the housing... to the right are the LED bulbs in sockets...
made a lens out of styrene I had from HO modeling "glass block"
batteries fit inside, 8 AA's, flat front looks kinda odd but ok to me.
not pictured is a strip of foam lining the bezel, I used the adhesive style for sealing drafty doors, it holds the aluminum sheet and styrene lens against the front of the bezel... I then lined the inside with some other foam bits I had, to keep all the batteries and wiring and such in place.
Carl.