Whilst building my LED version of this lamp i wanted to make the light from the bulb more natural and for the bulb to look more as if it was still working. This is the result.
Step 1: What You'll Need
Rotery tool e.g. Dremel
Soldering iron & solder
Jet flame lighter
Hot glue gun
Standard frosted bulb, bayonet cap BC(frosted glass as opposed to powderd)
Low voltage halogen reflector bulb (the smaller the better)
AC/DC mains adapter of about same voltage as halogen buld with wattage a bit below that of the bulb
Step 2: Open the Bulb
Using a cutting disk cut just as the cap is crimped smaller. Do this carefully as the black glass inside will crack
Ease the cap open DO NOT JUST PULL it off, it should still be connected by two thin wires cut these with scissors near to the top and leave connected to the base.
Step 3: Breaking the Glass
**Involves broken glass and if you cut yourself its your own fault**
The best way I have found to do this is by using the cutting disk on the dremel to press lightly onto the glass surface to leave a mark, keep it there and a crack should appear. Using the cutting disk you can extend and change direction of the crack until it encircled the bulb and the top comes off.
Step 4: Dulling the Edges
**Involves broken glass and a lighter if you cut and burn yourself you probably shouldn't be doing this and it is your fault not mine**
Now the top of the bulb is off you probbily not want sharp edged on it so take your jet lighter and the edges until they go clear. this has the added bonus dof making the edge slightly thicker and less likely to break.
I tried doing this with a small blow torch but the flame was too hot and caused the glass to shatter so i returned the my lighter.
The halogen bulb will be going into the body of the light. So you remove the vacuum tube I did this by snapping the end off with pliers then using a cone grinding steal or whatever its called on the dremel pushing gently down the center of the tube which breaks apart nicely.
Step 6: Breaking the Halogen Light
**Involves braking more glass just don't hurt yourself**
Because of the thick glass used in the reflector breaking requires some force. To stop shards of glass flying everywhere I thought it wise to put the bulb in a plastic bag, which i proceeded to crush in a vice. Remove the hopefully unscathed bulb from the broken shroud, you may need to use some pliers to break off some of the glass that is held to the bulb with the white ceramic cement.
Step 7: Connecting the Bulb
Solder some short wires to the base of the bulb and then cut the pins off at this point. Next solder these wires to the ones connected to the cap of the bulb (detailed in step 2) and check to see if it works. If it does well done if not find out what happened.
Step 8: Sealing It All Up.
Using epoxy resin secure halogen bulb in the base of the cap and then secure the cap to the rest of the bulb.
Step 9: The Desk Lamp
Because i wanted the smashed bulb to be visible I cut the cowling of the frount of the lamp.
Next i cut the existing lead off the lamp and attached the connector for the AC/DC adaptor and hot glued it into the gap the cable ran into.
Step 10: Put It All Together
Connect the bulb to the light fitting and power on, and behold light from a shattered bulb. And reattach the light fitting to the housing (I find removing the light fitting from the housing makes connecting the bulb that much easier)
Step 11: Fin
You are now done. Go and astound your friends and family