VXCL, I've gotta give you much, much props!
That looks like a headache-inducing job.
Great effort, great job - now let's see some shots!!!!!!
I honestly don't know if "size matters" with these setups - but in the world of lighting in-general, the larger the reflector and/or lens assembly, the more light is usually the result - speaking purely in terms of "throw." Get a load of why SureFire increases the diameter of their reflector housings for their "TurboHead" equipped tactical lights, as well as why they've gone to a convex lens for their Executive series incandescents, and you'll see what this typically means.
Additionally, look at legendary units such as the BigBulkHead reflector assembly on the CandlePower enthusiast discussion Forum.