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DIY Brass Horse Lamp ReFit 3.7 volt Battery Powered LED

Picture of DIY Brass Horse  Lamp  ReFit 3.7 volt Battery Powered LED
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Yes you guessed right another LED lamp. This excellent Brass Lamp makes a nice edition to my collection. And this can be done with any lamp should you choose to build a custom LED bulb for your lamp GO GREEN! Save some of your hard earned cash to buy supply's for Instructables!
This build should only take few hours to complete. I hope you find it enjoyable to make as I did with this build. 
These 3.7 volt Lithium batteries really light these LED's up!
 
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Step 1: Tools And Parts

Picture of Tools And Parts
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TOOLS NEEDED:

Butane torch
Needle nose pliers
Soldering Iron & Flux and solder
Wire strippers  
Small Flathead screwdriver 
Razor knife
Hemostats


Parts:

9 LED Flashlight from dollar store or any Home Depot  carries them for 2.99 or cheaper.
Some lengths of copper wire. (Needs to small enough for 2 of them to fit down the hole in the Socket)
1  3.7 volt Lithium cell phone battery.
1  Single pole toggle switch $3.39 At Radio Shack.
1 USB female connector.
1 USB male connector. 

Step 2: Removing the cord

First depending on you either cut the cord here or refer to pic 3.

1.   Now use the flat head screwdiver to gently pry off the brass housing be careful not to mar it up Its antique! 

2.   The housing is off.

3.   Pull off the carboard insulator to expose the wire screws.

4.   Use the flat head screwdriver to losen the screws and remove the the light bulb socket from the lamp and pull the wire out of the bottom of the lamp as well.

Save you cord for another project down the road or start recycling that old wire.



Step 3: Preparing The Socket

Picture of Preparing The Socket
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This small brass tab is laying down inside the Socket I lifted it to show the hole underneath it.

1. You want to use the needle nose pliers to carefully break this off by bending it up & down.
 
2. Line up the Socket & Insulator and cover and slide into place.

Step 4: The Bulb

Picture of The Bulb
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I will be using the same technique to make this Bulb as I did with the http://www.instructables.com/id/USB-LED-Lantern/ 

First things first SAFTY! Light bulbs are under pressure and can explode in your face or cut you badly Please wear eye protection and gloves before trying this.
You need to heat up the screw cap IT WILL STINK and smoke, My basement smelled liked burnt wire for hrs...  I used an old sock to provide some padding be very careful with your torch as sock's catch fire easy keep a fire extinguisher handy and if possible do this part outdoors.
1. with some pliers in hand heat up the screw cap evenly and slow too much heat at once will crack your bulb as seen by photo's. Once it is hot gently grab with some pliers and twist off slowly try not destroy the cap as it make's a great cover for the light board.
Brass screw caps will be more rigid and take  more abuse then the normal aluminum caps on 99% of house hold light bulbs. These light bulbs are tempered glass take your time heating up the glass so not to crack it but you can shape this glass as it will melt with a small butane torch. Once the screw cap is off break out the center filament carefully then even more carefully heat up the edges and shape it to fit the light board. this whole process took me about 5 to 10 mins of time.

I realize I cheated here with the photo's however its the same idea just a different style bulb so plz forgive me for being lazy on the photo and the Text for this step.

Step 5: Assembly Of The Bulb

To finish preparing the Bulb you will need to drill a small hole big enough for 2 wires to fit through on the screw cap. Drill slowly as the inside of the cap is glass, if you take your time you will not need a glass drill bit.

1.  Solder your hot wire and ground wire to the LED Light board.

2.  Feed the wires through the screw cap,  I used no adhesive in the screw cap in case the bulb gets broken I can easily get the light board out to reuse again.

3.  For this Bulb I used clear Silicone to glue the light board to the bulb. The silicone took a while longer to dry then the RTV blue I used on the lantern bulb. Once the silicone is dry your bulb is done.

4. Feed the wires through the Bulb Socket and gently screw until just snug DON'T OVER TIGHTEN THE BULB.

Step 6: Installing The Switch The Battery & Wiring The Lamp

1. Feed the light bulb wires down the tube.

2. The hole was already there for the switch  from the old cord, So install the switch and start the wiring.

3. For this Instructable I used USB connectors for the battery and the switch as it makes for easy recharging of the battery.

4. There are 4 wires in a USB cable we only want to use the RED and BLACK wires so cut off the GREEN and WHITE wires.

5. Solder the RED wire from the USB connector (dealers choice on male or female) to one side of the switch.

6. Solder the Hot wire from the LED light board to the other side of the switch.

7. Solder the Ground wire and Insulate all connections.

8. Solder the remaining USB connector to the battery RED for hot BLACK for Ground.

9. Plug in your power source and turn on your New Antique LED battery powered Lamp!
I like the idea of not having to use incandescent bulbs for my antique lamps, but I’m wondering if this is worth the effort if you have to charge the battery with the appropriate phone? It’s a good hack in theory, but I think I’ll stick to compact fluorescent bulbs instead.
jimmysymo2 years ago
Hello grasshopper,I have a 3.7 cell battery and wanted to use for a similar type project,
and I have the recharger,but was told that I CAN'T charge without the use of the whole phone,IS THIS CORRECT??? ...Really like your works
Grasshopper1221 (author)  jimmysymo2 years ago
Thank you jimmysymo,
Yes, You will have to use the phone as the charger for your battery, Be sure to use the right battery for the phone. As long as it has a full charge it should power a LED for some time. I hope this helps. Feel free to ask anytime.
You have answered my question and thanks much for the link!
Grasshopper1221 (author) 2 years ago
I made this to recharge my cell batteries http://www.instructables.com/id/Make-a-USB-battery-charger-for-cell-phone-batterie/
and also I use the cell phone that the battery came from, if you are good with soldering iron you can solder wires to said battery and still have it fit in the phone.
I find that using these old cell batteries have allot more power and are easy to recharge if you have the mindset to do it. Hope I have answered your question well enough.
Cheers!
Very cool! One question: how would you go about recharging these 3.7 volt cell phone batteries?
Beautiful lamp! (Where did you find a neat lamp like that?)
Anyways I wanted to share a recent discovery of mine... a few weeks ago I found some nice halogen lighbulbs that are inside a standard "Edison" incandescent lightbulb at my local dollar store (Dollar Tree), not only that but they were packs of 4! Anyways when one of them burned out the other day I decided to see I could easily pull out the halogen bulb and base without breaking the outer glass bulb... and with a quick bit around the base with a "dremel" cutoff wheel, to cut off the brass base (wasn't needed really, I just wanted to keep the base intact as much as possible...) Anyways (I digress yet again...) I was easily able to pull out the halogen lamp intact along with keeping both the base and to outer glass bulb intact...
(the lightbulb looks a bit like the one below, but it wasn't a globe...)
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Thank you. I found this lamp in the trash, Hard to imagine somebody putting that in the garbage.

I am looking forward to your instructable on your light!!
Winged Fist3 years ago
Cool lamp! I particularly like the idea of splicing a usb cable on to an old cellphone battery to be used as a lamp power source... Great idea... that I may have to borrow;-)
Grasshopper1221 (author)  Winged Fist3 years ago
Thank you winged Fist! I'm glad you like it or the idea of it, feel free to borrow anytime! :)