How to make your own LED lightbulbs by claudiopolis
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a tutorial to making commercial-look-a-like LED bulbs.

After many attempts to make all sorts of LED-conversions I finnaly found one solution that is simple and efficient. Of course, you do need a great amount of patience in making this but when you consider the countless hours of pure light -low consumption you'll get, it's all worth it. This tutorial is about converting regular GU4(MR11) halogen bulbs to LED bulbs while maintaining full usability as 12V light bulbs that can be used in indoor task or accent lighting.
 
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Step 1: You'll need the following stuff to start working:

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- one halogen bulb (burnt or new since they are really cheap) with no glass cover on front.
- LED's - as many as you want. You may want to keep this number reasonable since more than 22 LED's will make you work painful.
- online acces to http://led.linear1.org/led.wiz , a great LED array calculator you can use to figure out the resistors you'll need depending on your number of LED's and the supply voltage.
- Super Glue & compound glue. You can use other glue as well but super glue sticks fast and I recomend it.
- solder wire, moderate soldering skills, solder gun
- one small piece of 0.2mm aluminium sheet (this is used in printing industry, I work in this field and there are a lot of aluminium plates around here). Any offset printing shop will be kind enough to give you a used one since they use hundreds each month. A cut-out Coca-Cola can will do, once you straighten it.
- a paper perforator (office type, 2-hole punch)
resistors (depending on your needs)
- a few other common household items along with a good amount of patience.
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FBIRoyLindell says: Mar 17, 2013. 8:51 AM
Great instructable.

I have a question - won't this design draw just as much power as an ordinary halogen light-bulb? I understand that LED's use much less power, but surely the rest of the power is going to the resistors within the circuit to maintain the appropriate voltage/current?

Just wondering, thanks.
claudiopolis (author) says: Mar 17, 2013. 1:30 PM
Hi there. The short answer is no, this design is much more economical than the halogen bulb. It may not be as bright - but that actually depends on the LEDs used. I'm attaching here an example of a 12 LED array, powered by 12V. As you can see, the resistors together only dissipate 1.2mW. The entire array takes just 721.2mW, that's less that 1W.
Things change when you use high-power LEDs. In that case you need a special LED driver circuit to power those, and that's even more efficient than resistors.
Untitled-1.gif
CharmingCharlie says: Nov 3, 2012. 8:50 PM
Where can I but LEDS like that? I looked up where to buy resistors and people said radioshack or some other electronics place.

But what about those leds? Thanks
claudiopolis (author) says: Nov 4, 2012. 3:07 AM
The same place. Radioshack. LEDs are "Light-Emitting Diodes" so any electronic parts vendor should have them. Look for the higher luminosity ones. They're better and you'll get more light.
dagob says: Feb 29, 2012. 5:30 PM
And what if I want to make it 220v?
olio says: Sep 6, 2012. 2:08 AM
Get "big" LED with driver for 220 voltage.
seraine says: Jun 11, 2012. 9:00 AM
There's a small typo here - it would be firm, not ferm. Other than that, nice work.
claudiopolis (author) says: Jun 11, 2012. 1:01 PM
Done. Thank you! My English is getting rusty here in Romania.
siamonsez says: Feb 1, 2012. 6:58 PM
I bought a packet of leds that came with 200 ohm resistors. The calculator says to use 1 82ohm resistor per led which is 3-3.2v @ 20mA with a 4.5v power source. After playing with the calculator a bit a can't find any instance which asks for 200ohm resistors, but using wolfram alpha to calculate 4.5v with 200 ohms of resistance, it says 22.5 mA which is near enough the proper current for the leds.
I don't know if i'm misunderstanding something but it seems to me that these are at odds, any help would be great.
Are the 200 ohm resistors meant to be used with a higher voltage? I'm assuming a 1x array because the pack came with the same amount of leds and resistors, is that wrong? can someone explain what will happen if I wire:
(4.5v) > (3vLED) > (200ohm resistor).
edraq58 says: May 29, 2012. 11:26 PM
If you have 4.5v power supply to use with led that rated 3-3.2v @ 20mA, to calculate the resistor is: (1.) 4.5 v (power supply) minus 3.2v (voltage drop accross the led) which in your case is= 1.3 volts
(2.) Divide 1.3 volts to .02A ( 20mA) = 65 ohms.
To be safe you can go higher resistance such as 68 ohms or 70 ohms.

I hope I gave some ideas.
bas98 says: Jan 8, 2011. 4:08 AM
Why do you need the 1 ohm resistor??
panchavanparivendhan says: May 21, 2012. 1:28 AM
so that the led wo'nt burn
asafche says: Jan 14, 2012. 5:08 AM
See this. it will explain way - http://led.linear1.org/why-do-i-need-a-resistor-with-an-led/
claudiopolis (author) says: Jan 8, 2011. 11:02 AM
Just to be on the safe side. The LED calculator reccomended it so I used it. It protects the LED from overdriving by reducing the voltage a bit. You might skip it but you'd better be sure of the voltage applied.
ramhardikar says: Aug 9, 2011. 7:31 AM
Useful i'able.

where did you get halogen bulb with no glass cover on front?
claudiopolis (author) says: Aug 15, 2011. 5:44 AM
local chinese low quality store. You can use a glass-covered one too and follow the same guide until you get to the emptying phase when you just us the hammer to remove the inside of the bulb. Then when you have an access hole for a small screwdriver just slide that in until it reaches the glass from the inside. Use the hammer again to pop it out. I made this in my hand using protection gloves and the front glass popped out in one piece pretty easy.
beehard44 says: Nov 25, 2011. 11:10 PM
or you can also use a nail, place it on the socket side then break the glass cover. Works for me.
beehard44 says: Nov 25, 2011. 9:08 AM
very useful in my current project. I just don't know whether a joule thief can handle 10 LEDs attached to it...
XOIIO says: Aug 8, 2011. 11:52 PM
You misspelt Fir as Ferm on the hammering part.
claudiopolis (author) says: Aug 15, 2011. 5:45 AM
sorry about that. But you got the idea, right? :-)
XOIIO says: Aug 15, 2011. 1:19 PM
yeah, and I i missed the m, my keyboard was sticky lol
abadfart says: Feb 27, 2011. 1:19 AM
how bright is it? do you think its bright enough for a projector?
aamwalid says: Sep 11, 2010. 1:17 PM
Thanx 4 the idea, but please can you tell me how did you manage to cut the aluminum disk in a perfectly round shape that would fit into the reflector ???
hirocaster says: Aug 21, 2010. 7:35 PM
Anyone knows if this bulb works with regular halogen bulb MR16 powersupply?
mcastles says: Aug 10, 2010. 3:17 PM
Nice work! : )
akinich says: Jul 29, 2010. 9:52 AM
nice!!!!!!!! can i do this with infra red leds? will its proformance be good? please reply akinich
claudiopolis (author) says: Jul 31, 2010. 1:47 PM
Yes, as long as you respect the forward voltage and current of those infrared LEDs. The performance depends on the leds used, there are lots of them, with different ratings.
akinich says: Aug 6, 2010. 10:15 AM
thanks for replying akinich
shooper3 says: Jul 31, 2010. 11:16 AM
What are the best leds to use there are 1000's. I'm replacing a pool light and need very high brightness.
hirocaster says: Jun 14, 2010. 10:48 PM
This led bulb equals to how many watts? I mean, it equals to incandescent bulb of...let's say...50w?
oddysea682 says: Jun 9, 2010. 10:07 PM
Im going to use this instructable to add leds to a fluval edge fish tank
jm1820 says: May 28, 2010. 7:49 PM
Just wondering, is "compund glue" the same as 2 part epoxy resin glue ?
claudiopolis (author) says: May 29, 2010. 6:46 AM
Yes, it's about the same. It's grey when mixed and dries. I chose it because of its higher viscosity, the clear epoxy is too liquid and it drips easily until it dries. But this thicker one stays put. You could use anything you like, there aren't that big forces on those legs, the only problem is the drying time and if it stays there or drips away until it dries.
jm1820 says: May 29, 2010. 7:23 PM
Thanks for that info.
Its just that I have never heard of compound glue before.
Just wondering, does the stuff you use, have a trade or brand name ?
claudiopolis (author) says: May 30, 2010. 12:45 AM
Yes, it does but it's a local band. You should go to a DIY store and ask someone to recommend you a cement-like glue. You are interested in something that has a bit more consistency. Anything will do.
drhall says: May 28, 2009. 1:08 PM
Noticed the diff values for the 5% tolerance & placement for the resistors ... yep I know Bad Boys Only Ravish Young Girls But Violet Gives Willngly ... still mystery.
joerice01 says: Mar 22, 2010. 4:09 PM
 its ( bad boys raped our young girls but violet gave willingly)
e.g. 0=black 1=brown 2=red 3=orange 4=yellow 5=green 6=blue 7=purple  8=grey 9=white
 
static says: Mar 24, 2010. 11:44 PM
Don't forget to append Get Some Now for the tolerance color band.
Gold 5% Silver 10% None 20%
BytePilot says: Mar 22, 2010. 10:44 AM
Careful...

Bad Boys Ravish Only Young Girls But Violet Gives Willngly.

Black, Brown, Red, Orange, Yellow, Green, Blue Violet, Grey, White.

Brown   Black         Red
1      .         0    x10^    3   =1000 =1k

noname420 says: Mar 24, 2010. 8:34 PM
Lmfao i love it how everyone has a different color code thing to go with it

mine is

Bad Booze Rots Our Young Guts But Vodka Goes Well
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