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I'd look at glue laminating a couple of strips of thinner ply to the top section instead of routing it. You should be able to bend some 1/8" to fit inside the canister if you are careful. If it cracks you can ghetto up a steam bender to help it. You would lose a small amount of inside...

The light is basically a cylinder. A cylinder (or any shape tube really) in compression is, as demonstrated in that video, somewhat resistant to collapse when loaded in compression.

Looks like there is enough room for a squeezer in there at least. Couple of ways you could do it.. I would put the countersunk through and go at it with a domed former to squeeze it. You may need to practice on some scrap to get the length of the rivet correct to get it to form the dome...

If there is no real need for a performance upgrade of your existing stuff, consider repacking your existing NiCad batteries. The sub C size cells are relatively cheap and repacking is relatively simple. I recently repacked four DeWalt 18V NiCad packs for just over $80 Australian.

And its almost guaranteed to be stolen...

Hyundai is OK. Kia, not so much.. I'll take some pictures for you when I get a moment later today.

Some reading material on the subject for those that are interested.. http://www.emersonindustrial.com/en-EN/documentcenter/ControlTechniques/Brochures/CTA/HVACR/WHP_HarmonicMitigation.pdf

So replacement cylinder is $450. If you are comfortable in your ability to weld a repair that'll hold operating pressure then do it. If not send it out to a local welding place, it wont cost anywhere near $450 to have it done by a pro.

Operating pressure?

Mildly disappointed to find out that some, not all, of the Metabo 18V LI bundle I bought recently to replace my aging Dewalt are made in Korea or China...