Introduction
In this comprehensive guide, we will demonstrate how to transform a damaged LED floodlight into a robust, 15-watt high-power flashlight using recycled materials. This project emphasizes sustainability by repurposing an old floodlight and common household items, resulting in a powerful illumination device suitable for various outdoor or emergency applications.
Materials and Tools Needed
- An old, non-functional LED floodlight
- Two clean soup cans
- Two MT3608 step-up (boost) converter modules
- Two 2S 18650 lithium-ion battery holders
- Four 18650 rechargeable batteries
- Two mini rocker switches for power control
- Scrap wire for connections
- Hot glue gun and glue sticks
- Soldering iron and solder
- Wire cutters and strippers
- Power drill with appropriate bits
- Screwdriver set
Step 1: Disassembling the Old Floodlight
Carefully dismantle the LED floodlight by removing the outer casing, lens, and internal components. Use a screwdriver or pry tool to open the plastic housing without damaging the LED module or lens. Once exposed, desolder the LED assembly from the power supply board, ensuring you keep the LED intact if it is still functional. Test the LED by applying a 36V power source; if it lights up, it is suitable for reuse. If not, source a compatible high-power LED for the project.
Step 2: Constructing the Flashlight Body
Utilize two standard soup cans to build the main housing and handle of the flashlight. Cut a precise hole at the bottom of one can to fit the LED module securely, and create a side opening on the other can for mounting the battery packs and boost modules. To form the handle, cut a large enough opening on the side of the second can, allowing for comfortable grip. Use hot glue to attach the handle firmly to the main body, ensuring stability. Customize the cans by trimming and shaping as needed to accommodate internal components while maintaining durability and ease of access.
Step 3: Preparing Batteries and Boost Modules
Insert two 18650 batteries into each battery holder, connecting them in series to produce a total voltage of approximately 8.4V per pack. Since the LED requires around 32-36V, set each MT3608 boost converter to output 17V. Connect the two boost modules in series, combining their outputs to achieve the necessary voltage level. This setup ensures the LED receives a stable power supply, resulting in a bright, focused beam.
Step 4: Wiring the LED and Boost Converters
First, solder positive and negative wires to the LED terminals, making sure to insulate and secure the connections. Connect each boost converter’s input to its respective battery pack, ensuring proper polarity. Adjust the output voltage of each boost converter to 17V. Link the positive output of the first boost converter to the positive input of the second, creating a series connection. Attach the LED’s positive terminal to the positive output of the second boost converter, and connect the LED’s negative terminal to the negative output of the second boost converter. This configuration supplies the necessary voltage for optimal LED performance.
Step 5: Final Assembly and Testing
Secure the battery packs within the designated compartment in parallel configuration, connecting all positive terminals together and all negative terminals together. Install the switches to control power independently or simultaneously, depending on your design preference. Connect the power source to the boost converters as per the wiring diagram. After completing the wiring, double-check all connections for security and insulation. Power on the device to test the brightness and functionality of the flashlight. Make any necessary adjustments to the voltage settings or connections, then finalize the assembly by sealing the housing with hot glue or screws.
Conclusion
This recycled LED flashlight project not only provides a high-power lighting solution but also promotes sustainable practices by repurposing old electronics and household items. With careful assembly and proper safety precautions, you can create a durable, bright flashlight ideal for outdoor adventures, emergencies, or general use.
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