3600 Lumens LED stand build

[Concours.John]

Some of you know I`ve been experimenting and contacting people on an LED replacement or supplement to halogens. After trying out different set ups this really IMO fits the bill. I`ve tried billboard wash and others but the one thing I`ve noticed is it`s not a Brinkman. The one thing with a Brinkman is how you use the focused light to view defects. A wash just gives you general light. Yes it does show defects but there is not a way to move your eye from a focused point to see the defects around. The one thing I hate is working to have to pull something out in the sun to be sure. This is always a definite way to check your work but requires time. I might add there is no subsitute. The other is constantly picking up an inspection light to check work.

After the last halogen failed I was stuck with replacement but also came up with an additional light.

The Parts
Home Depot 1200 Halogen Light stand $60.00 You can buy the dual 500w for $35 which will work

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight027.jpg

2 Home Depot CMM03120 $80.00 ea

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight028.jpg

2 Aluminum case white exposed rectangle enclosures $3.49 ea

1 Bag of enclosure screw in blanks (4) $3.20

I`ll be using the Husky stand for the build and the harness and boxes from my dead 2 500w Lutron halogens. The husky lights will go on the Lutron stand. The reason for this is the Husky has flat stock bars to futher support the boxes Ill be using. The Lutron has round stock.

All of this is preformed with no modification to the stands or lights making warranty not an issue. The only thing modified is the $3 boxes. It is all waterproof and look as original (other than white fixture/boxes)

The objective is a seviceable/upgradable yet professional looking assembly. This is also aside from the plug a waterproof build. Great for outside.

First the boxes are drilled to accept the original mounting hardware. I squared mine to match the bolt but a bigger hole with a star washer will work.

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight020.jpg

The screw was then pulled flush into the square hole I made.
http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight021.jpg

The housing is then attached with the original thumb screw through the factory hole.

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight022.jpg

The assembly is then mounted to the box per directions with the included
hardware/bracket. (this is no different then changing a fixture at your house)
An exterior outlet seal was used to seal the fixture to the box even though the wiring will be concealed in the factory harness box.
The screw in plug was used and drilled to feed wires though and use the seal that comes off the donor harness boxes.

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight023.jpg

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight024.jpg

The wires are fed through the gromet (hard to see 1st pic) then holes drilled and tapped using box as template. Box is then mounted.

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight025.jpg

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight026.jpg

Finished Product

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight031.jpg


http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight030.jpg


http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight034.jpg

Lets light it up! Nice wash but what about the details.

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight036.jpg

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight035.jpg

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight033.jpg

http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight032.jpg

Now on light blue The light was not moved

The Rear
http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight037.jpg

Fender
http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight038.jpg

Fender
http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight039.jpg

Qtr
http://i1219.photobucket.com/albums/dd437/concoursjohn/LED%20light%20stand/beetleandLEDlight040.jpg

I really like how this light can be placed at 3/4 view and still see all the 3/4 veiw for inspection. This really reduces the amount of time moving fixtures. This also caught the slightest micro marring on the light blue.

These are the first pics with this camera. Im still fiquring out settings but they are better than my phone.

Thanks for looking. Any questions feel free to ask.

One note I have the motion detectors set on 10min. I like this because they stay on as long as there is motion within ten minutes. If I walk away they turn off saving hours on the lights. There are lower settings which will work the cycle resets as long as there is motion without loss of light. The motion sensor could be disabled also. I just like being able to walk away and have the lights turn off on their own.

Another note the lights still detach from tripod on the upper half as intended for lower work without clearance or balance issues with fixtures or wiring.

[Concours.John]

I`ll add that I added sealant/silicone to the top entrance gaps of the black electrical boxes to further weatherproof.

[mrclean81]

Holy crap..this was genius. You have built the ultimate light stand my friend :)

[doctordon]

Very nice indeed!

[Concours.John]

For those interested here are the specs if bulit this way.


Uses 76 w of power total

47 lumens per watt efficiency per fixture.

Equivalent to 300 w of Halogen but in the 5600k daylight spectrum. Total

Color accuracy 63 but may be a little higher because two fixtures

50,000hr bulb life

1yr warranty on fixture since no modification including not cutting wire length.

Heads are fully adjustable for light spread

1 Hr build time from unboxing to use

Almost 50/50 balance front to rear. Feels near perfect by oz.s from handle.

Here is a pic off the stand...

http://img.tapatalk.com/a689581f-8b6c-4a34.jpg

[Todd@RUPES]

Very cool John!!! Thanks for sharing!!! :rockon:rockon:rockon

[mamut]

That is sweet...how much did everything cost?

Edit: never mind, lack of reading skills lol /facepalm

[CH.Detailing]

This is awesome! I needs me one of these..

[TacoHerder]

Pretty clever ideal there. Wish I had a set place to clean so I could get some lights like this. As an laser and flashlight fanatic I carry a laser and flashlight with me all the time. I carry the laser b/c this time of year the birds tend to swarm the trees and power lines so bad you cant even hold a conversation with someone in front of you. Its totally safe to shine it at the birds eyes(birds have avian eyes) and it always sends them flying away. Anyways when at work I like to use this little guy.
http://i48.tinypic.com/ruy4ck.jpg
Its 1000 lumens, uses a 16340 battery, has a magnet at the end, 16 mode, and its water proof. As you can see its bright for a little guy.
http://i50.tinypic.com/2ymvzgl.jpg

[BobbyG]

Holy smokes John, that`s a great idea and man does that throw a lot of light! I already have a stand so guess what`s next!! :bigups

[Wors]

Great idea. The LEDs are very bright. Thanks for sharing the process.

[Rocket]

Nice job John. I like how bright it is.

[tropicsteve]

great idea john, especially for anyone who has worked under the heat of several halogens in the summer. great light output and power savings too. thanks !

[Ronkh]

Think I need to borrow this and try it out, before I can comment.........

:)

[RZJZA80]

Great idea and work, I`ve been trying to do something similar myself but I can`t seem to find good LED lights for the project that lights up as well as the 500w halogens do