My little sister needed a new wall light for her dressing.
She asked me to give it the looks of a spotlight with the wide beam angle of a regular light.
The result is this wall light.
The total cost was around 35 dollar.
Step 1: Materials and Tools
- Wooden board (MDF 12mm)
- LED (BRIDGELUX - BXRA-W0401-00000 - ARRAY, WARM WHITE, 400LM)
- Power supply (12v)
- LED driver (700ma)
- Opal glass
- Round pinfin heat sink (80 mm)
- Two screws (M3)
- Two wall plugs
- Two hook screws
- Pair of compasses
- Solder iron
- Diamond drill bit (40 mm)
- Drill bit (45 mm, 40 mm, 6 mm)
- hole saw (90 mm)
- Miter saw
- Glue gun
- Wood glue
- Bar clamps
Step 2: Drawing
Start with two pieces of 10 cm by 40 cm. and one piece of 8 cm by 1 cm
The material I used was MDF (12 mm thick).
I had them precut at a local wood shop, but you could easily saw them yourself from a bigger piece.
Take the two 10 cm By 40 cm pieces and make a mark from each end straight in the middle at 5 cm.
Take a pair of compasses and draw a half circle (10 cm in diameter) on each mark.
Take one piece and draw a line 1 cm from the edge of each long side.
Draw a line in the middle of each piece from the long side to the opposite long side.
Step 3: Sawing, Drilling and Gluing
Use a jig saw to saw the half circles out.
Take the piece with long straight lines and drill 90 mm holes on the markings.
Drill a 40 mm hole, 9 mm deep on a marking of the other piece. Drill a 35 mm hole on top.
Take the piece with the 90 mm holes and saw the inside out (use a jigsaw).
Use wood glue to glue the two pieces together.
When the glue is dry saw the hole piece in half, than saw a 12° angle on each piece.
Glue these pieces back together.
Glue the 1 cm by 8 cm piece in place: see picture (where the two pieces meet on the piece with no hole).
This serves to fix the lamp to the wall.
Step 4: Sanding and Painting
Properly sand the hole piece.
After sanding you can paint your lamp fixture in any color you like. I chose white.
Step 5: Heat Sink
The heat sink I bought had no holes to attach the LED to the heat sink.
Draw a straight line on the flat side of the heat sink. Shift your ruler to decide where the middle is. This isn't the most precise way to determine the middle, but it will do the job.
Place the LED on top of the heat sink and make markings where the screws will be placed.
Drill a 2,5 mm hole 4 mm deep on the markings.
Step 6: Power
Solder the driver to the LED. Make sure the polarity is correct and don't burn the LED.
Screw the LED to the heat sink.
Installing the driver to the power supply.
The power supply didn't fit in the lamp fixture by a few millimeters, so I removed the outer case.
Use a glue gun to glue the power supply in place.
Connect electrical wires to the output of the power supply.
Solder these wires to the input of the LED driver.
Step 7: Glass Work
The glass plate I got from my local hardware store. It is opal glass
Use a 40 mm diamond drill to cut out a glass disc.
Lay the glass disc in the 40 mm hole of the lamp fixture.
Now place the heat sink on top of the glass plate and fix it with a wood screw.
Step 8: Wall Mounting
Drill two holes (6 mm) in to your wall at the desired height spacing them 6 cm from each other.
Put wall plugs in to these holes and screw hooks in to them.
Attach the electrical wires coming from the wall to the input of the power supply.
Be careful: make sure the power of these wires is off.
Attach the lamp fixture to the hooks.
Step 9: Finishing
I hope my little sister is happy with her new wall light.