Super Bright / Variable Brightness LED PANEL

In this Instructable I am going to show you how to make super bright, very sturdy, properly cooled, variable brightness, accurate color producing 72W LED PANEL for photography, video work or any general lighting. This LED panel's design focuses on the lighting quality, durability of the panel and the LED strips longevity.

My new, more advanced DIY LED Light (more efficient - same illumination at 50W, more powerful - 100W, has active cooling and is ~35% lighter) - https://www.instructables.com/id/DIY-Studio-Light-...

Provided Amazon links are affiliates

TOOLS YOU'LL NEED:

Jigsaw https://amzn.to/2rg4uXx
Clamps: https://amzn.to/2TZjxlk
Sanding paper: https://amzn.to/2KSWWD7
Small drill: https://amzn.to/2U5QQmL
Countersink drill bit: https://amzn.to/2E6GcYd
Utility knife: https://amzn.to/2SoiDgy
Diagonal cutting pliers: https://amzn.to/2E8vOz5
Wire Stripper: https://amzn.to/2E8Qk2W
Soldering kit: https://amzn.to/2Q613Bf
Fretsaw: https://amzn.to/2Qxwa8k
Hot glue gun https://amzn.to/2PdCgpI
Screwdrivers and hex bit sockets

MATERIALS YOU'LL NEED:

Aluminum plate ~3.15 mm, 0.125 inches: https://amzn.to/2PdeA4E
Plexiglas / Polycarbonate sheet: https://amzn.to/2U3L0m3
PVC U Profile: https://amzn.to/2PfLrWC (like this)
LED STRIP 90+ CRI: https://amzn.to/2Sl1HYr
Camera Flash Hot Shoe Mount Adapter: https://amzn.to/2Q3gHxk
High-Speed PWM Dimmer 8A: https://amzn.to/2PeiOJp
12V 8A Power Supply: https://amzn.to/2DZA5nZ
11 Inch Articulating Arm: https://amzn.to/2Q3iItv
Similar DIY Project Box: https://amzn.to/2QxElRW
12V power socket: https://amzn.to/2EaAV27
Electrical tape: https://amzn.to/2QsKK0P
Wood glue: https://amzn.to/2E8Baus
Paint (local hardware store)
Thick wires (local hardware store)
Thin wires (local hardware store)
Screws, nuts, washers (local hardware store)

Step 1: Preview of the LED Panel That We Will Be Making

First, some different angles of the LED Panel.

Like what I do? Consider becoming a PATRON! This is a great way to support my work and get extra benefits! https://www.patreon.com/DIYPerspective

Step 2: Preparing Aluminum Plate

First you need to cut an aluminum plate (ideal thickness of aluminum plate 3-4mm) to 28.4 x 21.2 cm size. Sand sharp corners.

Then drill three 5mm holes in each side for screws and wires.

Use 25 x 20 cm printed template of your LED strips or you can use mine (https://drive.google.com/open?id=1cRCqYTaRL_Kdp8ds...), mark and drill holes that individual LEDs won't end up under the screw holes.

Use countersink bit drill that flat head screws wont be sticking out of the panel.

Step 3: Plexiglas / Polycarbonate Sheet Cutting

You need to cut the Plexiglas to the exact same size as the aluminum plate (28.4 x 21.2 cm).

First you need to cut grooves into the Plexiglas. Groove depth should be about haft of the Plexiglas thickness. Now you need to clamp the Plexiglas and bend it until it brakes. Use level tool, wood board or anything similar to bend with.

Then drill 5mm holes in all corners of the Plexiglas in same places like on the aluminum plate.

Test that screws will fit in all corners.

Step 4: PVC U Profile Cutting

Cut the PVC U profile to length of 21.2 cm. Easiest way to do that is to do longer rough cuts first and then trim pieces to 21.2 cm of length.

Step 5: Placing Electrical Tape

Place an electrical tape on the both sides of an aluminum plate. This will prevent LED strips from short circuit.

Puncture holes with screwdriver where the tape covers all the previously drilled holes.

Then mark spots with interval of 1cm on both sides of the aluminum plate. This will help to glue the LED strips at correct angle and spacing.

Step 6: Choosing Good Quality LED Strips and Gluing Them

On build like this, you should only use good quality LED Strips. Cheap LED strips has really dull and unnatural colors compared to more expensive ones.

Cut 5 meter LED strip to 25cm pieces. Now you have 20 pieces of the LED strip, which you need to glue on the aluminum plate.

Just don't forget to add and tighten the screws, because you won't be able to do that later.

Step 7: Making Side Contacts

You need to cut two 20 cm length thick wires and mark 20 spots on each wire, where you'll need to cut protective material.

Also cut more protective material in the middle on both thick wires. There we'll be soldering other wire which will be routed to the back of the panel.

Then hot glue both wires to each side of the panel.

Step 8: Soldering All LED Strips

Cut protective material from the thinner wire, twist it and cut it.

Now you need to solder all the positive LED strip contacts to the thick wire in one side, and in another all the negative contacts to other thick wire.

Step 9: Finishing Soldering

Add electrical tape to protect contacts.

Cut away some electrical tape that you could solder the wire which will be routed to the back side of the panel.

Add hot glue around the wire that you couldn't pull it out.

Step 10: Holes Drilling in PVC Profile

Drill holes on the PVC U profile in the same spots like on the aluminum plate.

First just drill on the PVC profile's back side and place it on the panel.

Now use smaller drill bit and drill pilot hole (you can do it by hand, PVC profile is quite soft).

Finally, from other side drill full size hole (5mm). Do this on all other corners.

Step 11: Placing Plexiglas on the Panel

Place Plexiglas under PVC profiles. PVC profile is quite soft so it's easy to bend it. This makes placing Plexiglas on the panel much easier job.

Step 12: Screwing Plexiglas

Add screws and tighten nuts, but DO NOT over tighten, that will crack Plexiglas.

Step 13: Making Base

Cut some parts from 6mm plywood for the LED panel's bracket. Yours might be different, it depends on the DIY electronic component box (the box in which we'll need to put dimmer and 12V power socket) size.

Then drill holes for the screws which are in the middle of the aluminum plate. And also don't forget to drill holes for the electrical component box.

Now glue all parts and leave it to dry.

Step 14: Camera Shoe Adapter and Painting

After glue completely dried up, you need to cut hole for the camera hot shoe adapter with a fretsaw. Don't cut the hole too big. Camera hot shoe adapter should fit very tightly.

Then paint the bracket with any paint you like.