Tension wire LED spot frame

thingiverse

Because of ordering time and high cost, I designed a super simple tension wire LED spot holder. Two printed parts and some basic hardware will get the job done. # Bill of Materials * 4 bolts M5x20 * 2 M5 hexagonal stud connector nuts * 1 bolt M4 x15 * 1 locknut M4 * 2 bolts m3x15 (with small or turned down head dia 4,6mm) * 2 nuts M3 * 1 MR16/GU4 ceramic lamp holder with wires * blank steel anodized wire 1,5 or 2 mm ##Putting it together Carefully remove the support from the M5 holes using an M5 drill. This support is added in the design. With a drill and a saw or grinder, make a small slit in the connector nut. The width of the slit depends on the steel wire diameter. The depth should be 50% of the length of the nut. Mount them according to the pictures. Mount the fitting with the m3 bolts. Tighten the bolts carefully not to damage the ceramic material. You can put some blue thread lock on the nuts, or use locknuts. Mount the clip with the M5 bolt to the base. Use the locknut to tighten the bolt just enough so you can change the angle of the clip. Solder the fitting wires onto the connection nuts. You can also use crimp ring terminals and put them under the mounting bolts inside the frame. ##Mounting Put 2 screw-eyes on both sides of the tension wire. On one side, connect the steel wire with wire clips to the screw-eyes. Keep the wires a bit longer so you can put them in a connection block, making sure not to short-circuit. If possible, add some protection sleeves to the ends of the wires. On the other side, do the same and add some turnbuckle wire-spanners. When everything is set up, connect a 12V power-supply to the connection block. scad files attached. You can modify them according to your needs! Sincerely, Jan!