Archive for February 4th, 2017

Bandsaw Worklight

Having hacked back the end of the USB gooseneck extension, a tweak of the COB LED heatsink mount for my desk lamp produces a smaller version for a 1.8 W LED:

Chip On Board Heatsink Mount - Bandsaw Lamp - solid model

Chip On Board Heatsink Mount – Bandsaw Lamp – solid model

That fits half of a random heatsink, bandsawed just to the far side of the middle fin and milled flat.

Ream out the 5 mm hole with a #8 drill for a snug fit around the gooseneck, jam gooseneck in place, dab epoxy on the corners of the recess, mash the heatsink in place, solder wires to LED, smear epoxy on the aluminum backplate, clamp while curing:

USB Gooseneck - LED assembly

USB Gooseneck – LED assembly

And it looks pretty good, if I do say so myself:

USB Gooseneck - on bandsaw

USB Gooseneck – on bandsaw

The hook-n-loop tape holding the cable to the bandsaw gotta go, but should suffice until I conjure a better mount.

The alert reader may wonder how a 9 V COB LED runs from a 5 V USB cable with nary a trace of a voltage booster to be seen. Well, that’s not really a USB cable any more; I paralleled the red+white and black+green wires for lower resistance, then hacked a 9 VDC power supply into an old USB hub:

Hacked USB hub - PCB mods

Hacked USB hub – PCB mods

I ripped out the upstream USB plug, hotwired the 9 V supply where the 5 V USB wires used to be, soldered jumpers on the downstream sockets to short the outer two pin pairs together, razor-knifed the power leads going into the epoxy-blobbed USB controller, and declared victory:

Hacked USB hub - in use

Hacked USB hub – in use

Admittedly, that “In Use” LED runs a bit brighter now.

I have a few other tools on that bench in need of LED lights; when I build ’em, they can all plug into this hub. No reason to invent new connectors & cables & all that. It may need a power switch.

Turns your stomach, eh?

The OpenSCAD source code as a GitHub Gist:

 

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