Light Bulb Base Repair

Intro: Light Bulb Base Repair

Introduction
Have you had a light bulb base oxidize and stop working? Furthermore, when you remove the bulb, the bulb comes out and the base remains in the socket? The reason for this instructable is to replace the base of an LED or CFL light bulb.

The Story:
One night the LED flood light stopped working. When I went to replace the bulb, it came out and the base stay behind. What a pain. Of course, it was supposed to be a simple twist out, twist in job. Not a repair to be done at night, so the next day I removed the base from the socket and inserted a new flood light.

I started to think just because the base separated from the light, could the bulb still work? I attached the bulb to a power cord and Yes, it did work. Wow. Now I started to think could I replace the base? Yes, I think I could… Where do I find a base? It is not an item on Amazon. I removed the base from a burnt out CFL. With a “replacement” base, I can solder it to the baseless LED Flood Light.

A bulb without a base and means to repair.
Became another item trashed in despair.

Now with solder and glue,
this bulb is made anew.

Next Tools and Supplies

STEP 1: Tools and Supplies

Tools:
Soldering Iron (More than 35 watts)

Supplies:
Replacement Light Bulb Base,
Solder,
JB Weld,
100, 240 and 400 Grit Papers.

Let’s go replace the Base.

Next Replacement Base

STEP 2: Replacement Base

Align the replacement Base with the bulb wires.

The Hot wire to be aligned with the hole. The Ground wire is bent over the edge of the bulb and squeezed between the threads of the replacement Base and the threads of the bulb. See image with description.

Next Solder

STEP 3: Solder

Bend the “Hot” wire and solder to the replacement Base.

Use the Solder Iron and Solder to secure the replacement Base and Hot wire.

The highest Solder Iron I had, was 35 watts. It can be done, but will be easier with a higher wattage Solder Iron.

Next Clean Solder

STEP 4: Clean Solder

Here is where you will clean and smooth the soldered Base.

I used 100, 240 and 400 Grit Papers.

Next Secure Base

STEP 5: Secure Base

Here is where you use the JB Weld to secure the replacement Base to the bulb.

1) Mix enough JB Weld,
2) Apply it where the replacement Base and bulb meet,
3) Let dry,
4) Insert bulb and test.

Next Observations and Summary

STEP 6: Observations & Summary

Observations

I have found little information regarding how to prevent base oxidation, everyone knows it happens but there is not a consensus or easy solution on how to prevent this issue. This occurs because of heat and moisture.

My preventive intervention will be to loosen and tighten the bulb, monthly, at a minimum. In addition, after windy rains; take the bulb out and wipe the base and inside dry. The idea is to keep the bulb base and bulb socket dry, preventing the oxidation from building. Furthermore, removing the bulb should prevent any bonding from occurring. I will be exploring other options to replace my constant interaction.

The benefits of this design are:
1) Removing repairable items from the waste stream,
2) Reusing items saves money,
3) Knowledge is a powerful tool.

Summary
I am satisfied with the results.

Comments

[trglou]

Might I suggest Vaseline Petroleum Jelly works very well for this. Works great on battery post and cables as well.

[richwithjayne]

On all my screw-in bulbs I coat the thread with 'Copper slip' grease which allows easier removal when the bulb died.
I believe was developed to be used on car parts to prevent corrosion.
I also use this on my threads of copper plumbing compression joints, make it a lot easer to do up and undo when necessary.

[ezman]

Thank you for Reviewing and Commenting.
I will add this to my grease list.

[shloime]

if you use a cfl bulb as a source for your replacement base, be careful not to break the glass - fluorescents contain mercury that should not be released. they need to be disposed of as toxic waste.

[ezman]

Thank you for Reviewing and Commenting.
Yes, I was careful not to break the bulb. Very sound advice for everyone to be aware.

[Vaibhav216]

Wow ! It will really help thanks for publishing this :D

[ezman]

Thank you for Reviewing and Commenting.
Let us know when you apply this knowledge.

[scotchdrnkr]

To help prevent Oxidation use dielectric grease available at auto parts stores. Its usually used when you replace bulbs in an automobile but I find the stuff works great on all my outside lights.

[ezman]

Thank you for Reviewing and Commenting.

[waffleon]

Great Ible another thing you can use on the threads to stop the oxidation is to brush anticize
on the threads you can get it from auto shops and it's great to have on hand for use on all sorts of jobs that you don't want to lock up.

[ezman]

Thank you for Reviewing and Commenting.
Anti seize lubricant another tool to help with corrosion.

[JerryL1206]

I always use Dielectric Grease on the contacts of outdoor lighting. It can also be used to prevent corrosion on automotive light bulbs and plug-in connectors.

[ezman]

Thank you for Reviewing and Commenting.
Thank you for your contributions.

[RandyPerson]

Further note on effectiveness of dielectric grease. We have a vacation rental on the Pacific coast. Includes a couple strings of LED patio lights. Installed all bulbs with grease. 1 1/2 years later, decided to swap clear for colored for holidays. Clear bulbs were a mess, and a quick taste confirmed - covered by salt from the marine air. But 48 clear bulbs came out easily with no corrosion, and later, the colored ones (also treated with a fresh dab) did the same. I'm so glad I did an ounce of prevention. In working on other original electrical work, I could not remove wire nuts, because the corroded wires broke instead. Go grease!

[ezman]

Thank you for Reviewing and Commenting.
Solid testimony on dielectric grease, thank you.

[atkielskialan57]

In Regards to the ext. Spotlight repair-Well Done !
Some Recommendations in regards to any & all Electric Light Bulbs: Di Electric Grease-Apply lightly to Bulb Base and if possible, The socket
Itself ( obviously - Turn The Power Off FIRST!) and use a Bulb Gasket! They used to come with the light fixture when new-they usually break down with age. Get the Cork Type ( most hardware store’s stock it!). You can even give the Cork Gasket a very light coat on both sides of DiElectric Grease to keep it soft and pliable. And make sure your sockets are aimed slightly down to prevent water from getting inside sockets. All of these Helps Electric Connectivity and make’s future bulb replacement easier too ! DiElectric grease should be used on All
Ext. outlets & plugs as another precautionary measure. Keep up the Good Works!

[JohnD818]

Besides dielectric grease (auto parts stores, 3M makes a good version) you can use petroleum jelly smeared onto the base of the bulb.

[atkielskialan57]

Just plain old Petroleum Jelly from Dollar Tree is
the absolute least expensive way- Unless you have an unused one laying around. Also, can be used on the Battery Terminal’s on your car , truck, outdoor equipment … Just make sure your terminals are clean and bright before applying.

[ezman]

Thank you for Reviewing and Commenting.
I see there are so many uses for dieletric grease or PJ (in a pinch).

[SylvanB]

dielectric grease has the advantage of a higher melting point and may be a bit more safe around rubber and plastic. That said, for decades my parents and I used "Vaseline" petroleum jelly on bulb bases and plug prongs with no problems.

petroleum jelly can deteriorate natural rubber so think before using it... it softened and expanded the o-rings on more than one flashlight, so now I use a pure silicone plumber's grease on those (same as I use on water filter o-rings and gaskets).