Right Gents.
I have managed to complete the LED conversion into a lumicycle halogen can, we all had been dicsussing on here lately.
It is an easy conversion and uses a triple LED from Cutter, driver off Ebay and a heatsink off Ebay.
It uses the existing connector and switch of the lumi can.
As a lot of you requested i have tried to create a step by step guide, so here goes:-
Job 1 is to remove the bulb connector off the lumi leads and remove the wiring loom thus
before removing the loom trial fit the driver to familiarise yourself with how it fits.
the driver is one of these
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=250503990255&ssPageName=STRK:MEWAX:IT
The guy has sold out at the moment but should have a stock in week or two.
Job 2 is to file the boss of th heatsink. The heat sink is this one
this piccy shows before and after
the other bit of filing is to file a flat onto the heatsink to clear the flat on the can. about 13mm-15mm should do fine.
Job 3 is to file a very small flat onto the LED board carefully and solder the LED's
Job 4 is to solder the driver.
Solder the LED wires first
then after remove about 4-5 cores from the Lumicycle wires
this allows the wire to fit into the holes on the driver board. then solder those.
I cut the length of the existing loom wires to about 20mm longish.
Job 5 is to wrap the driver FULLY with insulation tape. This is to stop shorting on either the case or switch/power connector.
Job 6 is to position the switch outside the can, driver, power connector and Heatsink/LED as they would roughly fit into the can. This is why I said at the beginning trial fit the driver so you could see this in situ.
Then with the whole thing assembled install carefully into the can dry. Ie no heat transfer paste/adhesive.
This will allow you to tweak the position of things to get it to fit as it is quite tight.
here are a few shots of the assembled items outside the can for a bit of help
When you have managed to get it to fit dry (including adding the optic and bezel just to make sure). Dissamble and use heat transfer paste between the LED and Heatsink and then put some on the outside of the heatsink and re-install into the can
fasten the switch and power connector in place, put the optic in and add the bezel.
Job 7 connect the battery, switch on and open a beer.
Running at 680ma gives good light. I used a triple XRE LED which should give about 500-600 lumens whilst being driven at 680ma. Heat can be felt tranferring into the can so the heatsink/transfer block appears to be working well.
I use heat transer paste from Maplins and 3amp wire to connect from the driver to the LED's from Maplins as well.
Hope this gives a good story on the build.
happy LEDing
Chucky
