UPDATE-- UPDATE -- UPDATE
I finally dug into the pile of old reflectors. I have selected the worst and an average one to see what processes and materials would work the best. As of this week, I have the pleasure of reporting that I am encouraged by a MYLAR sheet material that is very shiny, self-stick, and hopefully durable enough to stand up to normal use.
Tests were performed using standard conditions-- no lens and a fixed camera exposure.
I used a battery charger on the same setting, and the same lamp, for all three, shining onto a flat white wall about 18 inches away.
Three tail light reflectors were chosen in the following condition for the comparison:
1) an old reflector in rough shape (no shine at all, badly corroded),
2) an old reflector in fairly good shape (sort of shiny, no corrosion), and
3) one with the new material lining the reflector dish.
RESULTS ARE PROMISING!
The first two images are very dark.
This first one is the old corroded reflector with a new HO lamp
This is the fairly good reflector, cleaned to remove dirt.
This is the re-coated reflector with the shiny new Mylar.
I will now be running accelerated life testing on the prototype to see if normal heating over several hours in a fully assembled light will cause issues.
Keep your fingers crossed!
Andy
