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Archive for December 7th, 2018

Halogen Desk Lamp Conversion

As part of converting the halogen desk lamp to LEDs, I replaced the hulking iron transformer with a flatter counterweight:

Halogen Desk Lamp - 12 V 20 W transformer

Halogen Desk Lamp – 12 V 20 W transformer

Under normal circumstances, you’d use something like steel or lead sheets, but Tiny Bandsaw™ can’t cut any appreciable thickness of steel and I gave away my entire lead stockpile, so I sawed disks from a pile of non-stick pancake griddles and drilled suitable mounting holes:

Parallel clamps in action

Parallel clamps in action

Another disk (from a formal aluminum sheet!) goes into the lamp head, with a trio of 3W COB LEDs epoxied in place:

Ex-Halogen Desk Lamp - 3x3W COB LED assembly

Ex-Halogen Desk Lamp – 3x3W COB LED assembly

The other side of the disk sports a heatsink harvested from a PC, also epoxied in place:

Ex-halogen Desk Lamp - heatsink fitting

Ex-halogen Desk Lamp – heatsink fitting

Realizing the head required only a little filing to accommodate the heatsink sealed both their fates.

A test firing showed the heatsink needed more airflow, which didn’t come as much of a surprise, so I milled slots in the lamp head:

Ex-halogen Desk Lamp - vent slot milling

Ex-halogen Desk Lamp – vent slot milling

Deburring the holes, blackening the sides with a Sharpie, and tucking a bit of black window screen behind the opening made the vents look entirely professional.

The small dome in the base originally cleared the transformer and now holds the entire 10 W LED driver, along with all the wiring, atop the counterweight sheets:

Ex-halogen Desk Lamp - base wiring

Ex-halogen Desk Lamp – base wiring

A cork pad covers the base for a bit of non-skid action:

Ex-halogen Desk Lamp - cork pad

Ex-halogen Desk Lamp – cork pad

I couldn’t convince myself filling in those sectors would improve anything, so I didn’t.

And then It Just Worked:

Ex-halogen Desk Lamp - in use

Ex-halogen Desk Lamp – in use

All without a trace of solid modeling or G-Code …

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