LED Replacement Fluorescent Tube

Step 6 Create a Bi-Pin Connector

A Bi-Pin Connector is the most common type of connector used in fluorescent lamps. The bi-pins commonly used have 12.5mm between two rigid pins. To create these connectors, take a piece of scrap wood and drill two holes approximately 12.5mm apart. It helps to use a drill press and digital caliper, but it can be done with a ruler and hand drill. The depth of these holes is not important, make them at least 1/2 inches deep. The holes should be 1/16 inches in diameter. Cut two 5 cm pieces of 14 AWG bare copper wire. Insert the two pieces into the drilled holes. Slip the end cap from the tube protector over the two wires now stuck into the scrap wood. Twist the two loose ends of the wire together ensuring that the other ends remain in the scrap of wood. Prepare some low-temperature melting plastic. This is usually done by simply boiling some water and pouring the granules in. Pour the molten plastic into the end cap making sure that the plastic is at least 3/8 inches deep and distributed evenly throughout the cap. Allow the piece to cool and when the plastic is fully cooled and hard, remove it from the wood. Trim the two wires coming out of the end cap to approximately 3/8 inches. You should now have a replica bi-pin connector that can be slipped into the end of the tube protector with no effort at all. Repeat this process to create another end-cap. When you have two completed, mark one as positive and the other as negative using a marker.