Introduction: Transformation of Malfunctioning Power Tool Into LED Lamp
I decided to experiment with Cordless Drill transformation into LED lamp because aspects:
ᐈ refurbishing and re-use of useless Power Tool with burned motor unit
ᐈ handy form of sturdy plastic body of broken drill equipped with two sets of Ni-Cd 12 V, 1,4Ah Battery packs as well as a well made battery charger
ᐈ stable standing, with weight on bottom of Lamp
ᐈ cheap 10 W LED chips and easy to get Fan and Cooler
ᐈ In case of 12-Volts Ni-Cd battery no necessity for further voltage and current modification (if mention LED chip is used)
ᐈ need of wide Angel and strong Light source
Step 1: What You Will Need for Re-transformation
ᐈ LED chip 10 W (this one is possible to cool down effectively with ordinary size of GPU ventilator and cooler of older generations)
ᐈ 2 pcs of Switches
ᐈ Fan and Cooler (from older GPU)
ᐈ Wires (old AC power cable can be source of good-quality 3 line copper conductor)
ᐈ Tools and etc. : Soldering accessories, screw-tap (to make thread for 2 mm (M2) bolt), multimeter, rotary tool for adjusting plastic interior of body, heat-sink paste, 4 pcs M2 bolts,
Step 2: Work
ᐈ adjust LED Chip to the Cooler. Optimal pilot hole for taping M2 thread to Aluminum Cooler is 1.4 - 1.6 mm. Add thermal paste under LED Chip and fix it with screws.
ᐈ Consider cleaning and repacking of a Fan bearing and cleaning of heat sink surface to obtain stable performance.
ᐈ Drill holes in plastic body for both of Switches or for only one, if switching Fan and LED in one time is preferred.
ᐈ Adjust all components into opened plastic body, make necessary changes by rotary tool and wire all elements up.
Step 3: Test
Test out carefully your re-cycled LED Lamp.
ᐈ check if you installed sufficient heat-sink and fan
ᐈ pay attention to make well isolated wiring of your circuit.
(Short circuited Power Tool battery can be dangerous or can set things to fire or blow.)