DIY LED Using 10 Watt Arrays

[mike31154]

Originally Posted by SeaHorse_Fanatic

Al is Aluminum. My lights use Aluminum bars connected into a heatsink. Dissipates heat well.

Small, light-weight heatsinks will have more trouble dissipating the heat from 10w emitters so you'll probably have to continue using fans.

Ok, I thought by Al you may have meant AI as in Aqua Illumination, a heatsink from the company that makes LED fixtures which you used in making your DIY. So how thick or heavy are these bars? Some photos, dimensions etc. would certainly help me visualize what you're talking about. The new heatsinks I have are advertised to work without the need for fans as well and they've been doing the job on the center row of lights for a couple of weeks now. So if I were to consider what you're proposing/using, I'd need more info. Where did you get them?

[mike31154]

Here's what I've come up with for a cover. Mostly built, but need to fine tune, stain, cut vent holes, trim the edges & figure out the hanging scenario. The existing brackets for hanging don't protrude far enough through the new top. I suppose I could hang it from the top itself, but then I'd need to bolt the top to the frame & I'd rather have the top easily removable, so just resting on the frame. I'll figure something out.

Ended up getting a sheet of 1/8 mahogany plywood & fastening that to the end pieces. Amazing how stiff 1/8 ply can be when you're trying to bend it. I had to make two more semi arcs to support the plywood & make it bend properly in the center.

[mseepman]

Nice job Mike. I like that look a lot! Do you have to drill for fans still on top?

[hillegom]

looking good

[daplatapus]

Nice job Mike. I actually kind of like the 3 ribs on top.
FYI, when you have to wrap a curve like that, see if your supplier carries wiggle wood. It's a 1/4" plywood, but all the layers are oriented the same direction so it can roll up to something like a 4" diameter circle. Extremely useful, and you don't end up with those little curling edges that are always trying to straighten them selves like regular ply does.

[mike31154]

Some progress on the cover and replacing outer rails of lights with larger heatsinks, sans fans. Heatsinks are mounted on larger 1 inch aluminum u-tube than when I did the center one, so more material to draw away heat. The center rail has been running fine without fans & the 3/4 inch u-tube for some time now, no issues with the LEDs, so not sure whether I'll redo that one with the 1 inch material. Still need to yank the old rails & mount the LEDs on the new ones, but lights are on at the moment. Might get it done tonight.

Came up with some artistry to vent the cover. A bit of work with all the drilling, but I think it should look & be pretty cool once I have it stained & mounted.

[hillegom]

wow nice
You are not only into electronics, but an artist as well
Well done

[daplatapus]

That looks sweet Mike, Nice work!

[mseepman]

Nicely Done!

[mike31154]

Thank you for the encouragement everyone! It's most welcome. I was up until past midnight yesterday replacing those two stupid outer rails of LEDs. Another few hours this morning hooking the wires back up.

The cover does have some flaws, a few cracks & tears from drilling the larger holes & stresses from bending. Don't show up in the photos! Nice thing about wood is that I should be able to patch it up & once the stain is on, will be harder to see the booboos. Will take a few more days until I finish it up. It certainly will be nice to have the mess of wiring covered up. I've read more than the odd post where folks tend to shy away from DIY fixtures due to the industrial look of the end product. Next build will probably involve a canopy, so it won't matter!

Electrical & instrumentation was my trade in the Air Force. I've taken on a few woodworking projects over the years since I enjoy that as a hobby. I work on my old 'yota & motorbikes too. I tend to take forever to finish stuff though.