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How-To make your own LED MR-16 Holders
the CrazyLightLady Super Cheap Way

Supplies
Plastic
Champagne Flutes with removable bases-You can find
these at Garden Ridge or any party supply store. They cost
about $7 for a package of 10, but if you're lucky you can find them
on sale for half that after Valentines or the June Wedding
crunch.
Bead
Stacker-I found these at both Wal-Mart and Hobby
Lobby. They're about $2.50 each and they make 5 lids for the
holders. Although the bases for the Champagne Flutes work for
lids, I had a problem with getting them water tight as the lids
don't have enough overhang to keep water from seeping into the
holder itself.
Duck
Tape for sealing the wiring holes and securing the
lid onto the holder.
Old
Soldering Pencil for burning the openings into the
holder. Use an old one if you have one, the one I used dates
back to my High School days, I'm not sure they even make tips for it
anymore, but it does work well enough so I don't mess up the tip on
my soldering station.
Socket
for the MR-16. I bought these from
BestHongKong when I purchased my LED MR-16s. They cost 23
cents each in lots of 100, but you can also make your own using
female molex crimp pins, just make sure you have the correct size as
different suppliers use different size male connectors on their
MR-16s.
Wire-The smaller the gauge the
better, it makes it easier to seat the bulb into the holder. I
used 20 gauge wire that I had stripped from all the old mini
lights I replaced with led strings in '06 and since the MR-16s run
on 12V DC, they don't pull enough current to worry about the wires
getting hot.
Heat shrink
tubing or electrical tape to insulate the wiring
splices.
Steel
Wool-You may or may not need this, I'll explain
later.
PVC
pipe -1" in various
lengths.
And of course, the usual assorted
tools necessary for splicing and dicing.
Assembly

First thing you'll need to do is burn a hole in
the side of the Flute to accommodate the wires for the light.
Use an old soldering Iron or Pencil for this as it really gunks up
the tip. You may also want to burn all the necessary holes
outside in the fresh air, as the burning plastic can really stink up
the house and I'm sure that breathing the fumes isn't real healthy
either.

You'll want the hole for the wiring to be about
half way down the side of the flute. If you burn the opening
too close to the top, it might interfere with the bulb sitting level
in the holder.

Burn a hole into the bottom of the stem of the
Flute. I found that no matter how much tape I used on the
holder, some water always managed to make it's way in. It's
better to let it drain out as the LED Floods don't ever generate
enough heat to dissipate any condensation that forms in the
holder.

Depending where you live, you may or may not
need to stuff steel wool into the stem of the Flute. This step
lets the condensation drain out without letting all the creepy
crawlies into the holder. I'm located in North Texas and the
winters here are generally mild so all the bugs that generally bite
the dust farther north, make a bee line for the light and this is
the only way I could stop them from taking up residency.

Thread the wires for the MR-16 through the hole
in the flute. It's easier to push the wires from the outside
of the flute up through the top opening than the other way
around.

Place heat shrink tubing on the wires, (I use
red for the positive pole so I don't have to try and figure out the
positive and negative sides every time I plug a bulb in).
Strip the wires on the MR-16 socket and the wires, slice and solder
them for a good solid connection.

Use a heat gun to shrink the tubing. You
also may want to shrink another red piece of tubing at the other end
of the positive power wire, it just makes it easier when you're
wiring the lights to your controller. I have a piece of
granite tile that was left over from construction that I use as a
rest for the heat gun when I'm done with it. It keeps me from
burning chunks out of the countertops in my workshop, plus it's also
great as a hot melt glue gun rest.

All shrunk up and ready for further
assembly.

Set the flute upright and push the socket with
the bulb in it down into the flute. Make sure you keep the
spliced parts of the wires completely inside the flute, so you
negate the possibility of getting any water into the splice
just in case the heat shrink tubing isn't totally watertight.
You also won't need to try and glue the bulb into the flute. I
did this at first, but found it served no purpose other than making
it harder to replace the bulb if I needed too. Don't worry if
the bulb doesn't sit perfectly level in the holder, you have to
place and aim the spot were you want it anyway.

Tape the opening in the side of the flute with
duck tape making sure you have the power wires heading down the
side. I used different colors of tape for the different colors
of the bulbs. Since you can't tell what color a LED flood is
until it's lit up, this just makes it easier for me to tell which
color I'm working with. One other little trick I found that
helps with keeping the colors straight is to color a few of the LEDs
with the corresponding color of Sharpie. It doesn't affect the
light output at all and does make it much easier to identify once
the paper tag falls off.

Place one of the bead lids on the top and tape
it down on both sides of the holder.

Place the Holder into a section of PVC pipe and
tape the wires to the PVC. You can make the PVC pipe any
height you need it to be. I have some that are 3' tall,
(they're behind the taller bushes in the flower bed), and some that
are only 6" long, (they need to be shorter to be able to hide them
better).
That's it. Now take them outside, push the
PVC pipe into the ground where you want it, aim the light where you
want it, hook it up to a D-Light DCx16
Board and enjoy!
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Remember this is my site and my opinions, I'm not
an expert at anything, if you have questions or
constructive comments e-mail me, and
finally, please don't post any of this
information on the TCL site or boards.
Thanks! | |
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