DeWalt DC527 LED Conversion Adapter

thingiverse

Hello Everyone- I have been wanting to convert my DeWalt hand Held Work Light for a while. Finally took the time to check the power usage of the original CFL bulb, and my own that I created from the cheap LED strip lights you buy on a roll. The original CFL bulb uses about 10.3W, where my roll your own LED bulb came in at 5.4W. Just about half the power usage and brighter. I used a 3/4" piece of gray PVC Conduit, 6" long. That's what I had lying around. I wrapped the LED strip around it like a candy cane. HELPFUL HINT: Before you just start wrapping, leave the sticky backing on and wrap it all the way. This will give you the length and the starting angle of the wrap. Use scotch tape to help secure it. The voltage converter is a cheap step down converter purchased from eBay. I used this converter for some other projects, so I had some history with it. https://www.ebay.com/itm/5A-DC-DC-Buck-Step-down-4-38V-to-3-3V-6V-9V-12V-24V-Converter-Voltage-Regulator-/262998248346?hash=item3d3beacb9a Once you open up your light, you simply unsolder the wires from the original board, and solder those wires to your new board. I do recommend adding a 2A fuse between the battery and the new board. The original board had a fuse on it.. The Off/On switch is a real switch, and not part of the original board. Just leave it as is. Another bonus. I found that my replacement converter board slides right into existing slots and stays snug. No other mounting stuff needed. Another bonus! See Image. Before you place a load on these converters, power it up WITHOUT YOUR LED'S ATTACHED and verify the output voltage. Since it is variable, I am sure it won't be at the 12V's required for the LED strips. (Mine was found at 18V on the output.) Pass your wires down the center of the adapter by drilling a small hole. See image. The adapter was designed for a tight fit and using 3/4" PVC electrical conduit. On the inside of the reflector, that plastic piece at the top that the original CFL bulb slid into is actually some sort of rubber. It squishes down on my new LED bulb holding it in place. Note: The reflector is conductive, so be sure your LED strip does not come in contact with it. And, the LED's get warm. Use at your own risk. Enjoy- Shins