Replace Low Voltage Bi-Pin Halogens with LEDs

Step 3 Mount driver in wood block

The key to getting this LED "bulb" to fit in the halogen fixture is to compactly mount the driver within the heat sink. This is accomplished by cutting a scrap of wood that fits between the heatsink legs and that has a drilled out center where we can hot glue the drive circuit securely. You can also drill holes in the heat sink legs to add screws if you don't trust the hot glue. This joint will take any insertion forces when installing or removing the bulb and will also hold the whole assy up against merciless gravity. I used a 3/8 inch drill bit to drill two holes side by side and joined them by wiggling the bit while under power. Crude yet effective. The result was a slot that the drive circuit fit into nicely. With the driver in the scrap wood, I filled the holes with hot glue to hold everything in place. Pay attention to how the wires exit the wood so that don't impede the pins interfacing with the light fixture.