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Old 11-10-2010, 03:19 PM
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Lightbulb DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

Why go through the trouble of making my own bulbs when I could just buy some from a place like V-LEDs? I wanted them to match my cargo LEDs exactly and the ones from V-LEDs were a little more purple.

First, cut the boards from prototyping PCB


Then paint the plain side white (not the side with all the copper soldering pads).

For the 194 bulbs, fill the bottom two outside pads on the narrow end with a bit of solder to create a bump. Then fold a solid wire (I used 20 AWG) in half and loop it around as in the photo. Use needlenose pliers to help form the wire and make it flat. Now that the wires have a slight bulge, solder them do the copper pads below so that they don't shift around when inserting the bulb into the holder. The bulge helps keep the bulbs secure once installed.





Now solder the LEDs and resistors (10Ω) to the boards. The lead closest to the side with a single row of solder pads is negative. Positioning them is easy: Negative Lead > -LED+ > -LED+ > RESISTOR > -LED+ > -LED+ > Positive Lead. It doesn't matter where you position the resistor in the array, this was just the easiest way I thought.







These bulbs are done! On to the 578s...

I used the resistor to make the negative lead. Then just chain the LEDs along going negative to positive, negative to positive, and so on.





Now grab your stock 578 bulbs and pull the end caps off.


Insert a screwdriver or something to enlarge the slots.


Now you can slide them onto your LED boards.



Wrap the protruding leads around and solder them to the metal end caps.





Fill the end caps with epoxy or potting compound to secure them.



And you're done!



Voilá!



UPDATE:
I had to replace a bunch of the dead superflux LEDs. I upped the resistor a little to 22Ω, hopefully that makes them run a little longer.

Since the soldering station was out and warmed up, I decided to make some straight-firing 194 bulbs for the liftgate and footwell lights. This first one I plan to use in the liftgate light, which is completely useless and will go unseen, so I rushed it. I cut the proto board w/scissors and didn't even paint it lol
For the footwell bulbs I will at least paint the boards to prevent the yellow colorcast. I ran out of superflux LEDs so I used some white 5mm LEDs that I've had sitting around forever. They're pretty bright but they have a narrower viewing angle (20°)

Construction is very simple. First, you need some bulb bases, like these: "Empty Wedge Bulb Bases"

Now you need to make the LED pill/module. For this I just cut a circle of prototyping board slightly larger than the opening of the bulb base. Then I soldered the LEDs in series as closely as possible. I used a 22Ω resistor, which should run the LEDs around 20 mA. You need to make 2 long leads that point down. I used the resistor for one, and a piece of solid 20 AWG wire for the other



Slide the module into the bulb base, making sure to get the leads through the little holes at the bottom of the bulb



Fold the leads over in the proper direction (they go in opposite ways) and trim if needed. I used a little hot glue to secure the module to the base



Here they are compared to my DIY superflux bulbs. They're definitely bright but not as bright, and the spread is narrower. The proto board created a nasty yellow colorcast but it's not as bad in real life, the photo exaggerated it



While I had it out, I also got some shots of the "cargo strip"






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Old 11-10-2010, 03:39 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

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Old 11-10-2010, 03:40 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

NO COMMENTS BRO!!!!! WOWOW!!! you took that write up and shitted on it!!! LOVE IT!!!! great work!
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Old 11-10-2010, 03:42 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

need 2 pieces of info bud!!!

1. what leds are they?
2. what resistors are they?

again awesome
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Old 11-10-2010, 03:47 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

haha thanks guys

Sorry, they're those 4-chip white LEDs from Oznium http://www.oznium.com/four-chip-led

10 ohm resistors. I chose to run these LEDs pretty conservatively since some of you guys have had a couple go bad. Four of these in series with a 10 Ω resistor runs them around 45 mA, which should keep them running for a long while. Don't worry, they're still plenty bright, perfect I think, not TOO bright.


UPDATE: The LEDs keep failing so I upped the resistance to 22Ω, hopefully that prolongs the life of them
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Old 11-10-2010, 03:49 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

awesome! any advantage to run them in series instead of parallel? did you do the back ones in parallel??? sent you a pm mr scientist

wow 45 mA huh? that means they're running at 1/2 power?
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member of Black, Tri-State, 6 cylinder club 08 Brilliant Black Laredo (JG 3.7L Squad)- k+n 63-1545,magnaflow 10436,mygig(ren), HID's 6k lows, 6k+3k fogs,dual turn leds,led brows,v-led interior leds, cargo led strip, reverse hids, 92 led brake lights, tinted tails,custom powder coated mesh grill, srt sways, 15% tinted windows,illuminated visors,shorty antenna, HH Class III, cargo liner, thule snowboard rack,kayak rack, bike rack

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Old 11-10-2010, 04:10 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

Quote:
Originally Posted by B.P.O.D View Post
awesome! any advantage to run them in series instead of parallel? did you do the back ones in parallel??? sent you a pm mr scientist

wow 45 mA huh? that means they're running at 1/2 power?
Running them in series allows for fewer and smaller resistors. If you ran the four LEDs in parallel you'd need a 1 watt resistor for each one, which would generate a lot of heat. It would also make for more wiring. Wiring them in series is easier and safer. For stuff like this, you don't have a lot of room to work with so the less wiring and components the better.

Generally, with LED retrofits you run strings of LEDs, which are then wired in parallel. You want to use as many LEDs as you can in each string given your source voltage, that way you don't need a bigass resistor. For example, these LEDs have a forward voltage of 3.5 volts. 4*3.5=14v so I wouldn't use any more than 4 for each string, or in this case, each bulb. I originally planned on running these LEDs at around 55 mA with a 8.2 Ω resistor but the closest thing Radio Shack had was 10 Ω and I didn't feel like ordering some then waiting for deliver.

They're running a little above half power but that sounds worse than it is. They're still BRIGHT.

I ran the cargo LEDs the same way, two 4-LED strings wired in parallel. That way color and brightness is 100% consistent all throughout the interior (I still have to do the footwell lights, and the liftgate light but I need more LEDs)

I hope this makes some sense
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Old 11-10-2010, 04:23 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

def made a lot of sense, i didn't think about each led needing a resistor if you wired parallel lolol.. the ones in the rear came with a resistor so i forgot

so you went with 8 leds in the rear??? i also ran mine in 2 packets of 3 in the rear leading to the wires. quick disconnects were key in the back.

when does production start?
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How To - LED BROW

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Old 11-10-2010, 05:49 PM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

Yup, 8 in the rear, 8 in the middle (4 on each side) and 8 up front. Perfectly balanced lighting

I'd like to give these a shakedown run before I make any for other people, I want to make sure they don't burn out in a week lol I also need to design the footwell and liftgate lights. Then I could offer a full plug-and-play interior LED upgrade
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Old 11-11-2010, 12:36 AM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

Night-use update: After viewing the lights at night, I honestly wouldn't want them any brighter. This output is perfect.
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Old 11-11-2010, 01:42 AM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

i need some blue footwell lights jdub......

i'll take on the assembly and everything......

i need help with the theory

so please post mup how you make those when you get a round to it PLZ.
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Old 11-11-2010, 09:50 AM
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Re: DIY Superflux LED bulbs (578, W5W/194) Plug-and-play!

i can just picture jdub sayin....

"i dont need no stinking purple bulbs, shit im just gonna make my own shiznit.."

a pic before i go-
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