10W led rechargeable worklight

I like building led lamps, and so i decided to modify a 10w led floodlight to make it like a work light with a stand and all .
there are 2 versions of the housing , one with premade holes and one with no hole , in case your lamp has different fixing points , feel free to take the design and remix it :D

The housing and the cover should be printed at 100% infill but the foot doesn't really matter , it can also be printed with ABS or PETG for improved resistance

How to build it

Components

here are all the components you’ll need:

• Boost converter https://bit.ly/3FsFnaA
• 10Wled floodlight https://bit.ly/3P0kaYX
• A switch https://bit.ly/3Bax8xo
• 2.5mm female jack https://bit.ly/3Vzc6Rk
• Tp4056 https://bit.ly/3B6msQv
• 1-2 18650  (for EU i use this site https://eu.nkon.nl/ )
• 18650 holder (optional)  https://bit.ly/3XVOVCn
• 6-10 m4x10 screws and 2 nuts

Start

Now that we have all the items, we first need to open the floodlight and remove the back completely

Led and converter

Then we can take the boost converter and turn the potentiometer clockwise until we hear a click, so it’s not boosting when we are going to adjust the power (it would damage itself and the led).
Now we solder the led to the output of the converter and a pair of wires to the input of the converter, we pass the wires through the hole. Remember to apply some thermal paste/grease to the backside of the led before fixing it to the housing.

Back housing

After passing the wires trough we can screw the back cover on, I used four m4x10, but I had to use a washer since it was too long, use a m4x8 for a better fit.

Batteries and tp4056

Insert the dc jack and the switch, and we can start preparing the wiring, take one or two battery holders and solder wires on the pins, then hotglue those down with a tp4056 and solder the battery wires to the battery terminals of the tp4056.

Wiring

Now crimp or solder the converter input to the switch ,remember to check the polarity and mark the positive wire ( i used a bit of tape )

More wiring

Now solder the output of the dc jack to the input of the tp 4056 and the output of it to the switch again , be careful of the polarity

End

Now put a battery in the holder and turn the switch on , the led should still be off , start adjusting the potentiometer on the converter ( i keep it at 11v ) and you should be done !
close everything up and attach the foot with 2 m4 screws and nuts , after that just recharge the lamp and you're ready to go , i used 2 2150 mah batteries and the lamp lasted 6h35m

Category: DIY