Dumpster Dive- ESL Lamp to Hi CRI LED MOD

Its not a Flashlight but maybe someone else likes it too.
At my old workplace we had to change the Lamps at the Office hall. And we should have thrown the Lamps in the trash. But i was allowed to take one for myself.
And now was the time to Mod this thing so i can use it in my kitchen. Original the Lamp is powered by 3 ~30W ESL Bulbs including a integrated/combined PCB for all 3 Bulps + the big copper packs that was filling the complete upper part of the Lamp. Sorry that i do not have Pictures from the old original ESL build.
Now the Lamp is using a SHARP 50W Meg Zenigata 4000K 3770LM 92CRI 50V LED.
The LED is mounted on a 2mm copper plate covered with a Glas lens (cut by hand). On the top side of the copper plate i glued (thermal glue) a old intel CPU cooler. I had to shorten the perforated metal ring by ~3,5cm. Then weld it back together and clean the edge. On one picture you can see the welding spot at the lower end (not my best work, but the material was burning away because i could only use a big mig welder). A little more metal work was also needed (making the plates for the Boost converter + the plate for the PSU + fitting the brass standoffs for the copper plate + fitting the lens and the fan . . . ). The fan on top was running at 5V (using a cheap small Buck converter) but i used it only for testing and it is only needed if i crank it up to 50W. At ~40W it stays cool enough without a fan. The LED is powered by a Boost converter (CV/CC) which is powered by a 24V 6A (i would say 4A) PSU.
To finish the light i have to clean the surface. I want to use fine sandpaper for amore rustic look or polish the SS. And maybe mod the Boost converter with external Potis so that i can regulate the output without opening the light. But for now i am happy that its working fine and i am realy happy about nice Hi CRI light color.











Love the mod TheOnlyDocc. It should look good in the kitchen. You are going to have to put a hand picture in there to give us an idea of how big it is. :slight_smile:

On the left is a BLF Q8 and on the right a modified TN-31

You just need a carry handle and a long extension lead and you would be set for anything.
The picture really puts in perspective how big your light is. Love it. :heart_eyes:

Nice work and a very cool looking lamp, love it!
Maybe one more pic of the lamp in duty in the kitchen?

I have luck. Living in an Old building with more than 3m ceiling hight. So i will place it right over my table and still have enough space. I have not tested jet if it is to bright at ~40W but it is easy to lower the output a little bit further when it is all done. Still have to find a nicer version of this nut https://www.picclickimg.com/d/l400/pict/160798614528\_/Messing-Ringnippel-M10x1-Außengewinde-Rundbügel-beweglich-Bohrung-durchgehend.jpg. And i am still not 100% sure jet if i use a steel cable or a steel chain.

And if i ever need a lot more light i can push the LED a lot harder than the original 50W (with propper cooling). Even sharp tested the LED with 1,5A resulting in ~5500lm. And thats not the end. But for more than ~1A i would need a different Boostconverter. This one is limited to 50V.
Have i mentioned that this LED has cost me only 3€ inclusive shipping ~5€. The converter 3,40€ the small one less than 1€ and the PSU 7€. The only thing that was not so cheap was the lens including the Aluminium ring. You can get them cheaper. But not this version. And i liked the optic of the lens package.
All together not much money. And because the LED is not getting very warm, the PSU gets only low load and the Boost converter is build for loads up to 250W i expect that it will live much longer compared to Lamps that you will buy at a furniture shop.

Very nice mod TheOnlyDocc. You say your putting this in the kitchen, is this a new way to fry eggs?
Just Kidding :wink: . I like your attention to detail, that should be the nicest kitchen light around. So look out for the neighbors, as their gonna want one too.

I like it. Except driver (in my experience ac-dc driver is usually more reliable that ac-dc ps+dc-dc driver) and cpu heatsink (I would cut each second fin, in current config closer fan=better heat spread), it is perfect. If you could use another heatsink (more distance between fins), I think it could work even better without fan. Distance between top and bottom of tube seems to be big enough to provide good natural air flow.
Have you got any artefacts in beam? I mean reflections from ss cone.

Very nice mod, but surely you have room for a battery pack in there? :slight_smile:

@kiriba-ru
I am always open for suggestions regarding the driver!
I like the combo because it is cheap, i can see no pwm flickering and i can easy controll the output (and i used a few of them already and they are all still working). With a little modding i could also set a min and max value with aditional potis and put 2 potis somewhere at the top so that i can regulate the output without opening the light. Sure there are many driver out there that can be controlled via App but i did not want to spend to much money on the kitchen light (that is something that i keep for the living room. Not tomorrow but in the near future there are plans for a more complex project).
I was first thinking about taking some finns out (for better passive flow). But at 40W and less there is absolut no need. It stays below 40° C (meassured on the copper plate as near as i could get to the led.
And regarding artefacts in the beam. So far i did not noticed artifacts. But i have to say that the lens helps to get a nicer beam. The light is spread more evenly, less concentrated in the hotspot. When its dark i will try to get a wall shot. But i do not know if my older hany will be able to get a usable picture. But i will try!

@eas
It would easy run on a battery pack with this CC/CV Boostdriver. A 4S 26650 pack with 5,2Ah would give you 60-90min at ~4000lm. But then you better fit a shoulder strap to the light. This thing is heavy. One reason why i did not mod it until now. The ceiling in my old living place was lowered with drywall plates. And the wood structure underneath was not the best. So i did not want to risk it all cumming down. Now i can drill in solid stone.

And here a picture for the people still on the search for a bigger flashlight. (like the youtuber AvE often says: More bigger more better

And i have to say. The weight distribution is not so bad. A little bit to much at the head but it would work :wink:

Cool :slight_smile:

I think it’s slightly too big for edc, no?