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Step 4Step two - make your holding disc.
Put the empty reflector aside since it's time to get to another task. It's now time to make the LED support.
You'll need a template so make yourself one OR download the attached PDF file featuring all the layouts you could use with this kind of bulb. I used graphic software to evenly distribute the 5mm holes on the disc. The disk size is up to you. More led's will require larger disks.
Print the template on paper and cut it out with paper scissors. Place it on the aluminium sheet and light glue it on its surface. This will be useful to cut the disc properly.
Take the aluminium sheet and cut out the holes using a office perforator. I found out mine cuts exactly 5mm holes in paper so for 5mm LED's it's perfect. Keeping it upside down, place the template along with the aluminium disc glued on it inside it. Cut out the holes after aligning the circles in the cutting hole. This should be easy and fairly quick. For this tutorial, I'll use 22 LEDs and a disk diameter of 4 cm. In this picture you can see another disk I made for 15 LEDs. It's easy and if you practice a little you can make this in minutes.
Just to avoid any errors, this IS NOT a heatsink! This kind of LED bulb will not heat at all! That's because the dissipated power is VERY small.
You'll need a template so make yourself one OR download the attached PDF file featuring all the layouts you could use with this kind of bulb. I used graphic software to evenly distribute the 5mm holes on the disc. The disk size is up to you. More led's will require larger disks.
Print the template on paper and cut it out with paper scissors. Place it on the aluminium sheet and light glue it on its surface. This will be useful to cut the disc properly.
Take the aluminium sheet and cut out the holes using a office perforator. I found out mine cuts exactly 5mm holes in paper so for 5mm LED's it's perfect. Keeping it upside down, place the template along with the aluminium disc glued on it inside it. Cut out the holes after aligning the circles in the cutting hole. This should be easy and fairly quick. For this tutorial, I'll use 22 LEDs and a disk diameter of 4 cm. In this picture you can see another disk I made for 15 LEDs. It's easy and if you practice a little you can make this in minutes.
Just to avoid any errors, this IS NOT a heatsink! This kind of LED bulb will not heat at all! That's because the dissipated power is VERY small.
LED LAYOUT2.pdf(595x842) 288 KB| « Previous Step | Download PDFView All Steps | Next Step » |
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9
Oct 14, 2008. 1:42 PM
kelseymh
says:
kelseymh
says:
At Step 4 -- Many different "models" of halogen projector/track-light bulb are the same physical size (the differences are voltage, wattage, or pin configuration). You might do future readers a service and attach your two very nice 15- and 22-LED templates as EPS or PDF files which we could then print.
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4
Oct 15, 2008. 9:08 AMclaudiopolis (author)
says:
claudiopolis (author)
says:
On Step 4 you will find all my LED templates, in PDF format.
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9
Oct 15, 2008. 9:32 AMkelseymh
says:
kelseymh
says:
Very nice; thank you! This looks like an A4 page? Hopefully we ignorant Americans will figure out to _not_ "fit to page" when printing ;->
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4
Oct 15, 2008. 10:41 AMclaudiopolis (author)
says:
claudiopolis (author)
says:
Yes, sorry, that is an A4 document. Standard size over here. Just print with no scaling and align top or bottom depending on the design you are interested in.
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