These are great to use in motorhomes/caravans or any 12v DC system you have, solar, wind or hydro... or even just using them in your car.
These LED discs I have here run on 12-16v DC and do not need any resistors.
If you have a 24v system, just run 2 of these in series to get your desired voltage.
They run at 0.96 watts, (20 of these will use the same power as 1 20w halogen)
OK lets get started.
Step 1: 1, What you need.
1x halogen bulb
1x length of thick copper wire.
1x length of 2c cable (.75mm speaker wire fine)
1x small screwdriver.
1x soldering iron and solder
1x glue, here I am using gap filler & clear tacky glue (hot glue gun is fine.)
1x vice grips, any clamping device is fine.
Step 2: 2, Gutting halogen bulb.
some have no outer glass lens, some only have cement holding the burner in and no glass at the plug end, you can just pick out the cement using a small screwdriver or bang it on a surface.
1st, put your bulb in a spot where it can stand up, I have used my solder roll.
2nd, grab your screwdriver and place it in the center on the lens, bang it with your pliers to smash the glass and then pick the glass out...(if you cut yourself, down tools, put your tools away and go to bed, this project is for bigger kids).
clean with a rag and make sure all glass is gone before proceding.
3rd, hold the halogen sturdy in your hand and bang the legs/connector bits on a flat surface... may take a while, but should soon pop the burner loose.
you should now have a gutted halogen.
Step 3: 3, soldering copper legs
Next solder on your copper legs to your wire.
Strip your cable about 5mm, tin it and then solder to your legs...like in pix.
If your solder is not sticking to your copper, try sanding it a little to remove the corrosion on the copper.
Then put a tiny bit of insulation tape around your connection, (just in case it touches inside your fitting).
Step 4: 4, Glueing legs in place.
Now leave over night to dry.
Step 5: 5, little touches.
Now its glued in place, grab a black or red marker and mark the bulb so you know which is the + and - leg.
Then put a little blob of solder on the legs on the outside, this will stop them being able to be pushed inwards if handled roughly.
Step 6: 6, Soldering LED
Step 7: 7, Gluing in the disc
I use 2 small blobs of hot glue to hold it in place before gluing though.
Step 8: 8, Trimming legs
use large pliers for this as it gives them a ==> making them eaiser to insert into fittings.
Step 9: 9,Adding 12v DC supply and testing.
Step 10: 10, Finished.
Now you have a finished light, here in the pic i have the one we made now with white LED's and other ones i have made with wharm white LED's.
The warm white ones put out light very similar to the original halogen but at 1/20th of the power required.
you will be simply amazed of the amount of light these put out for a led light.