I had a bit of a break from these things but got stuck in the last couple of days, I got the ball rolling by getting a mate, Simon to turn them up on a metal lathe at his work. Everything else I was able to do and was fairly straight forward just took I bit of getting my head around.
So heres what I came up with, theres a plastic lens thats sitting on top of the led and the led mounted to the heatsink with arctic silver thermal paste to transfer the heat. Heres a post I made around the time that I got them, so yeah its been awhile https://dsd32.wordpress.com/2011/10/02/xm-lt60/
And a shot of it mounted in the headlight, I used a speaker port to try and tidy up the hole they come out of and to try and stop dust and water getting in. Will work a lot better when I figure out how to seal it all properly.
DSD32 