http://www.instructables.com/id/Lantern-Torch-LED-Conversion/

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Lantern Torch LED Conversionby x2Jiggy on September 17, 2011

Table of Contents

Lantern Torch LED Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro:   Lantern Torch LED Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1:   Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2:   Disassemble Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3:   LED Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 4:   Install LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 5:   Complete LED Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 6:   Install Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

http://www.instructables.com/id/Lantern-Torch-LED-Conversion/

Author:x2Jiggy    x2Jiggy.comA tech and gadget enthusiast who enjoys building and creating DIY projects.

Intro:  Lantern Torch LED ConversionHarness the power of modern lighting technology by converting a standard lantern torch into an LED torch. LEDs provide the advantage of longer bulb life, reducedpower consumption (originally 750mA, now 320mA) and reduced heat. This project uses 32 LEDs which provides slightly more light than stock while using under half thejuice. I've made a video showing the basic steps involved in making the project. You'll be building a small LED light and installing it in the reflector. This light is thenconnected to the circuitry in the torch so it operates as per normal. If you're keen, take a few minutes to view then continue on to the detailed instructions.

 

Step 1: EquipmentParts:- 1x 6v Lantern Torch / Flashlight (Amazon)- 5mm White LEDs ( DealExtreme ) Any multiple of two. I used 32 LEDs for this one.- 1 Ohm 1/4W Resistors ( Amazon ) One resistor required for every two LEDs used.- Disc shaped wooden or plastic object that fits inside the reflector to mount the LEDs. I used a jar lid that I trimmed down.- Thin gauge wire.

*Affiliate links provided to suitable products on Amazon.com and DealExtreme.com

Tools:- Soldering equipment- Drill, tape and stationary

http://www.instructables.com/id/Lantern-Torch-LED-Conversion/

Image Notes1. Wire2. 1 Ohm 1/4W resistors3. 5mm White LEDs

Step 2: Disassemble ReflectorRemove the lens from your torch. You may need to remove the bulb before you can get the reflector out. Ensure nothings securing the reflector in as it can be a bitdelicate and may break if removed with force. In my case, the lens was attached directly to the reflector and had to be removed also.

Find or make a circular disc like object made from a thin wood or plastic that will fit in the reflector. I used a jar lid with the threaded section trimmed off for some bonuskludge points.

Image Notes1. Reflector

Image Notes1. Jar lid with the thread section cut off.

Step 3: LED Mounting HolesApply a layer of masking tape over your disc and rule a grid that will evenly space your LEDs over its surface. Keep in mind that you need to have an even number ofLED mounting holes. Once you're happy with your measurements, use a small drill bit to drill pilot holes. This helps to accurately reproduce your grid on the disc. Drill outthe pilot holes with a 5mm bit. I used some sand paper to clean everything up afterwards.

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Step 4: Install LEDsLED pairs are going to be connected in series with a resistor. Each pair will then be wired in parallel. Install a pair of LEDs and bend the legs to connect the positive leg ofone LED to the negative leg of the other creating a pair with a single positive and negative leg. Apply some solder to the join to secure the pair together. Continue until allthe pairs are installed.

A resistor will be added to limit the current applied to each LED pair ensuring only a safe amount will be supplied. This will ensure your LEDs lives are not tragically cutshort and you can enjoy the LED benefit of longer lamp life. Clip the negative leg and resistor leg to around 5mm in size and solder. Repeat for each pair. Although itdoesn't matter which way you attach the resistor, I'm a stickler for installing them all in the same orientation. You can now test each LED pair using the 6v battery for thetorch.

Image Notes1. 1 Ohm resistors added to the negative legs.

Image Notes1. All LED pairs installed without resistors.

Image Notes

http://www.instructables.com/id/Lantern-Torch-LED-Conversion/

1. Diagram showing a 10 LED circuit. Paired LEDs are connected in series with aresistor. Each pair is connected in parallel. Additional pairs can be added inparallel. Calculation and image from http://led.linear1.org/led.wiz.

Step 5: Complete LED LightWe now need to connect each LED pair in parallel which basically involves soldering all the positive legs together to make a single positive leg and the same for thenegative. Bend each positive leg over to connect to the one next to it, clip them to size and solder them together until only your single vertical positive leg remains. Whenconnecting the negative legs, ensure you're making the connection after the resistor so you don't bypass it. Adding the resistor raised the height of the negative legsallowing you to make connections over the top of your positive ones easily. Be careful not to accidentally connect any of the negative and positive legs together as yourlight won't function.

Once all your pairs are connected in parallel and you have a single positive and negative, connect a wire to each and extend these connections. It's not a bad idea toinsulate the solder points for these two wires with some tape or heat shrink tube. Test your light with the 6v battery and ensure all the LEDs light up. If they don't, examinethe connections to the LEDs that didn't light. Run the two wires through your reflector and secure the disc in with some glue. You now have a completed LED lamp readyfor installation.

Image Notes1. Single vertical negative leg.2. Single vertical positive leg.

Step 6: Install LampWe need to wire our new LED lamp into the current circuitry of the torch. A standard lantern torch simply has the battery connected to the globe through a switch. We'regoing to connect the lamp in the globes place. Cut the wire between the switch and globe terminal as shown in the attached image.

Solder the positive lead from your lamp to the wire connecting to the switch and the negative lead to the wire connecting to the globe terminal (I soldered my to theterminal directly). The globe used to make a connection between the globe socket and terminal (see images) however as he's absent we need to bridge this connectionwith a piece of wire to complete the circuit. Install your reflector and assemble the torch. Push the button and be smug, you have the Prius of lantern torches.

Image Notes1. Positive wire connected to the switch.2. Negative wire connected to the globe terminal.3. Connection between globe socket and terminal bridged with a piece of wire.The globe previously connected these two points but he's no longer welcomehere.

Image Notes1. Connection between globe socket and terminal bridged with a piece of wire.The globe previously connected these two points but he's no longer welcomehere.

http://www.instructables.com/id/Lantern-Torch-LED-Conversion/

Image Notes1. Wire to cut between the switch and globe terminal.

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Comments

1 comments Add Comment

 Kiteman says:  Sep 18, 2011. 3:55 AM  REPLYNice job.

Next challenge: replace the lantern battery with a re-chargeable battery and a winding charger.