Disassemble and hack a Philips flat 100 watt equivelent bulb to create a flat bulb capable of replacing a 100 watt halogen bulb.
Step 1: Buy the LED Bulb
Buy a flat Philips 100 watt equivelent bulb from Home Depot as shown. Mine cost about $8.
Step 2: Remove Metal Base From the LED Bulb
Use a Dremel tool to cut the metal piece on two sides then split it open and clip the wires loose. take care not to pull on the wires and break them loose from the electronics inside.
Step 3: Crack Open the LED Bulb Case
Use a razor blade to carefully cut the plastic seam all of the way around the bulb then pull the case open. The electronics can then be freely removed.
Step 4: De-solder to Temporarily Remove the Disk and Capacitor.
1) mark where the single RED wire is attached to the disc then use a soldering iron to heat the solder and remove all 4 wires. Set the disk aside.
2) Use the soldering iron to also remove the single capacitor on the back side of the circuit board.
Step 5: Re-assemble the Capacitor.
Re-assemble the capacitor on the top side of the circuit board. take care to ensure that the wire on the stripe side goes back into the negative terminal port. The negative port is labeled on the board.
Step 6: Re-assemble the Disk to the Circuit Board.
Re-assemble the disk to the circuit board ensuring that the red wire goes back into the same port. Orient the board above the disk as shown and solder all 4 wires into place.
Step 7: Test the Circuit and Complete the Circuit Board.
1) Attach an electric power cord to the two power wires and plug it in to verify that the solder joints are good. Redo solder joints if light doesn't work.
2) Use a hot glue gun to attach the circuit board to the disk.
3) Use hot glue to cover all disc solder joints.
4) Use hot glue to ensure that the power wires don't get pulled loose.
Step 8: Disassemble the Halogen Lamp
Disassemble the halogen lamp and remove the bulb housing from the decorative portion of the lamp. This housing is what protected the decorative portion of the lamp from the tremendous heat produced by the halogen bulb.
Step 9: Prepare the Bulb Cover to Fit the Lamp.
Take one plastic half and cut it until it fits into the bulb housing space. this will be different for every project. Mine fit after I cut the stem from the disk.
Step 10: Attach the Disk Bulb to the Plastic Housing.
Put a dab of hot glue on the cover and place the light disk in place. Add glue around the edge as needed to secure it fully.
Step 11: If Needed Cut Additional Room for the Circuit Board.
All projects will be different. Mine needed a tiny bit more room and I was able to get it by cutting a slot in the bulb housing. This cover originally protected the lamp from the halogen bulb heat, but since LED lights don't make much heat they can be cut if needed. test fit the LED bulb to ensure the fit is good.
Step 12: Affix the LED Light to the Lamp Housing.
Use hot glue to attach the LED bulb to the bulb housing. Take care to hide any holes and to keep the glue out of sight. You may want to also use a small fastener. Re-test the bulb to confirm that it is still in good working order.
Step 13: Assemble the Bulb Housing Back Into the Lamp and Test the Lamp.
1) Attach the LED power wires to the lamp using wire nuts.
2) Re-assemble the bulb housing into the decorative lamp housing.
3) Test the lamp. When it works you are done!! You now have an LED lamp that uses very little electricity and puts off almost no heat. The light is comparable to the halogen bulb and will last much, much longer as LED bulbs can last a decade or longer.
Happy safe building!!