Picture of Cordless Drill Rechargable LED Spotlight
I stripped the gearbox in my cordless drill that my mum gave me for xmas many years ago. I was going to throw it out  but I couldn't bare to waste two perfectly good batteries.  So I thought what can I do with them?  Brainwave make a spotllight with a low voltage down light.
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Step 1: Things that I used.

Picture of Things that I used.
Materials - Cordless Drill and accessories 
                     Low voltage Downlight kit
                     LED Downlight 

Tools -        Soldering Iron           
                     Wire strippers or Pliers
                     Electrical Tape
                     1hr of your time

Step 2: Disassemble cordless drill casing

Picture of Disassemble cordless drill casing
Important - Remove battery from drill before disassemble.

remove all screws and pull housings apart carefully

Step 3: Remove drive motor and chuck assembley

Picture of Remove drive motor and chuck assembley
Cut the two wires going to the drive motor as close as you can to the drive motor.  Remove drive motor and chuck assembley carefully and put them aside for another project.

Step 4: Strip and prepare wire connections

Picture of Strip and prepare wire connections
cut the downlight connector cable from your downlight kit to the correct length.  Leave an inch or two extra.  strip and twist all four wires ready for soldering.

Step 5: Solder wires and wrap each wire with electrical tape

Picture of Solder wires and wrap each wire with electrical tape

Step 6: Check for fit

Picture of Check for fit
Check the fit of the downlight globe.  Modify housing with a dremmel if required.  and use hot glue if needed.  
Put wires nicely in place being careful not to pinch them between the two covers.

Step 7: Reassemble and test.

Picture of Reassemble and test.
The 3 watt led downlight globe works great.  I did test it also with the halogen 50 watt downlight as well and you can vary the brightness using the trigger.  I think I will stick with the LED because battery life is substantially improved about 12 hours before i have to change the battery.  You can change the polarity using the forward/reverse switch.  The LED globe worked in both positions. I will try a dimmable led next time i go to the hardware store.

and best off all it comes with a carry case and a spare battery.  Thx mum.

russ_hensel5 months ago

Just a note to let you know I have added this to the collection: Cordless Drills Hacking for Other Uses !

>> http://www.instructables.com/id/Cordless-Drills-Hacking-for-Other-Uses/

Take a look at a bunch of project involving odd uses of drills.

and for even more drill info

>> http://www.instructables.com/id/Cordless-Drills-A-Collection-of-Collections/

MOHD771 year ago
very nice
sdsh2 years ago
Muy buena idea, tengo un taladro que se le quebraron los engranes, esta es una magnifica solucion para seguir utilizandolo, saludos desde Guanajuato, México
tim_n2 years ago
did you use any resistors?
trott (author)  tim_n2 years ago
Yes the variable resister that came with the drill, known as the trigger. Lol
mammasboy2 years ago
this is a fantastic idea, all i need now is to go shopping for a drill, lol
trott (author)  mammasboy2 years ago
Thx. It's been going for 24 hrs now. It's not as bright after that time because of the nicad battery. If your going to buy a new drill for this project I would recommend the lithium ion battery. Then it will stay bright till the battery is fully discharged.
good job
Thanks for the share! You did a nice job describing your process.
trott (author)  audreyobscura2 years ago
Thankyou. It was instructables led competition that inspired me. Unfortunately I was to late to enter.