Step 3: Remove the Bulb

Once the reflector is removed you can remove the bulb, If you have the patience then work away at the epoxy bonding the bulb into the housing until you have freed the bulb. Now remove the positive terminal from the housing.

If you do not have the patience then cover bulb with a cloth and SMASH it with a pair of pliers, now use a drill with a 6mm bit drill out the rest of the bulb. You should be left with a housing clean of the old bulb and any epoxy, check your LED for fit at this point. If the hole needs enlarging do this with a drill or Dremel and stone point.
Do you have before and after pictures of the beam? I suspect that the shorty reflector will spread the LED beam more than it did the incan bulb beam. Why did you select that LED? Was it for beam spread, power, output, or what? I think I would use silicone, too. I don't understand why you used epoxy, but it really doesn't matter as long as silicone would work.
After pictures added
I will take an after picture of the beam, however the bulb module used was already burnt out. I have another one that somewhere that may work I will see if I can dig it out. As for LED selection, I was not to rigorous in my selection criteria, I selected it on power, price and also the fact that it worked nicely with the 3v available. As described below I had epoxy close to hand (i.e no silicone), and did not consider that it would be any more work to replace the LED with a new one if needed than the original bulb. I'm sure silicone would work, however you would have to be much more careful not to move the LED off centre when forming the legs of the LED.
Nice. But why epoxy? Wouldn't silicone sealer work just as well and be easier to clean up?
I did consider silicon, there were two reasons for choosing epoxy. Firstly that epoxy sets hard and I considered that this was a benefit. Secondly that I had the epoxy close to hard. Also you can't glue a mini to your ceiling using silicon.
Silicone. Not Silicon.<br/><br/>Silicon == Computer chips<br/><br/>Silicone == Sealant as well as fake breasts.<br/>
Everything in my comment is correct. I mearly emphesised my reason for choosing epoxy. Let me now do the same for why i didn't choose silicon. The adhesive properties of silicon are only reached at temperatures higher than the melting point of the LED and housing. In its naturally occurring as silica (or silica dioxides) the abrasive properties would also scratch the LED. On the plus side when used hot the silicon can be made crystal clear much more so than the epoxy. Finally you cannot glue a mini to the ceiling with sand.
Silicon is not an adhesive, sealant, or any other type of gasket making material. It is an element, which is used extensively in computers for it's semi-conductor properties. Silicone on the other hand can be an adhesive, sealant, and a gasket making material. It can be clear to opaque, and it can withstand a wide variety of temperatures as well as chemicals. Your wording is wrong. Silicon is the incorrect word for what you were referring to--which is Silicone.
As it seems important to you, I accede your point. I am indeed aware that silicon is not adhesive or sealant. I'm sure it's just an artefact of an over zealous spell checker. Or my dyslexic mouse hand.<br/><br/>However as it's seems <a rel="nofollow" href="http://www.thefreedictionary.com/subtlety">subtlety</a> and <a rel="nofollow" href="http://en.wikipedia.org/wiki/Humor">humor</a> (a rather unsubtle clue to which was contained in the last line of my previous comment) are wasted here can I further regale you with the fact that what we know as &quot;Silicone&quot; are in fact not true Silicones as such a chemical bond (a double bonded S = O group, analogous to a ketone group C = O)is not found, but rather Polysiloxane (single covalently bonded S-O groups) compounds.<br/><br/>

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