DeWalt DC527 LED Conversion Adapter

thingiverse

Hello Everyone, I've finally found the time to convert my DeWalt handheld work light for a while now. After checking the power usage of the original CFL bulb and my homemade LED strip lights, I was amazed by the results. The original CFL bulb uses about 10.3W, while my DIY LED bulb came in at a mere 5.4W, nearly half the power consumption and brighter to boot! I used a 3/4" piece of gray PVC conduit, 6" long, which was just lying around. I wrapped the LED strip around it like a candy cane. HELPFUL TIP: Before you start wrapping, leave the sticky backing on and wrap it all the way. This will give you the length and starting angle of the wrap. Use scotch tape to secure it in place. The voltage converter is a cheap step-down converter I purchased from eBay. I've used this converter for other projects, so I was familiar with its performance. 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, simply unsolder the wires from the original board and solder them to your new board. I recommend adding a 2A fuse between the battery and the new board, just like the original did. The Off/On switch is a real switch, not part of the original board, so leave it as is - another bonus! I found that my replacement converter board fits snugly into existing slots without any additional mounting required. See Image. Before you load up these converters, power them up without your LED's attached and verify the output voltage. Since it's variable, I'm sure it won't be at 12V for the LED strips (mine was found to be at 18V on output). Pass your wires down the center of the adapter by drilling a small hole - see image. The adapter is designed for a tight fit with 3/4" PVC electrical conduit. On the inside of the reflector, that plastic piece at the top where the original CFL bulb slid in is actually some sort of rubber. It squishes down on my new LED bulb, holding it in place. Note: The reflector is conductive, so make sure your LED strip doesn't come into contact with it, and the LEDs can get warm - use at your own risk! Enjoy, Shins