I use bright lights for my underground video work in caves. Over the past 8 years, I have been using HID spotlights in combination with a Diffuser. The typical HID light I pack puts out about 7,000 lumens. I have seen 100W LED projects on YouTube and thought I would try to build a 200W LED that put out 20,000 lumen. It took me a couple of weeks to build the light once I received all of the parts. Sometimes in took 3-4 weeks to get parts from China (200W LED and Lens Kit). I was able to fit all of the components into the a plastic ammo box. Unfortunately, the powerful LED lights require a heat sink and cooling system, so this light is neither water resistant nor water proof (fair weather light). Attached is the Bill of Material for the light, which cost just under $200 USD to build. I would mention it is a flood light, not a spotlight due to the type of lens kit. A future project might be on how to figure out how to mount this in a Thor body and take advantage of its reflector. I think this would require some type of machining of the reflector.
Runtime with (4) 11.1v, 5,000 mah batteries: 27 minutes
Major Components:
200W LED
200W White High Power LED Optic Glass Lens Aluminum Reflector Fixed Mount Holder
Tollshop Plastic Ammo Box
Geeetech 150W Boost Converter DC-DC 10-32V to 12-35V Step Up Voltage Charger Module
Mcshow Yaln FAN D50sh-12c Fan 50*50*20mm 12v 0.27a 2pins 2wires Cooling Fan
* Supplier: Amazon
* Price: $8.99
* Used to cool Geeetech Booster. Fits perfectly on top of Booster's heatsink. Zip tied it to the Booster
(5g) Thermal Conductive Heatsink Plaster Viscous Adhesive Compound Glue For PC GPU IC
DEEPCOOL GAMMAXX 400 CPU Cooler Heatsink w/ 120mm PWM Fan w/ Blue LED
Kingwin 120 x 120 mm Long Life Bearing Case Fan CF-012LB Black
ZIPPY Flightmax 5000mAh 3S1P 20C Battery – 4 Pcs
ZIPPY Flightmax 1000mAh 3S1P 25C 11.1V, 1 pcs
* Supplier: Amazon
* Price: 6.78
* Used to power both of the cooling fans
Battery Wiring Diagram
Floureon 2 Packs RC Lipo Battery Monitor Alarm Tester Checker Low Voltage Buzzer Alarm with LED Indicator for 1-8S Lipo LiFe LiMn Li-ion Battery - 2 Packs
* Seller: Amazon
* Price: $7.99/2 Pack
* Used to monitor battery level on Lipo's
HXT4mm w/12AWG Silicon Wire 10cm (ESC side) (5pcs/Bag)
RadioShack SPST Rocker Switch (Neon), Catalog #: 2750692 – 2 Pcs
Misc Supplies:
Build Comments:
Build Pics:
Cut out a hole in front of the case for heat sink cooler pipes to pass through.
Note: The hot part of the light is outside the case
Drilled holes in both sides of the case for air to pass through
Misc Pic (Coolmax component attached to heat sink plate from lens kit)
Drilled holes in the heat sink plate (lens kit) to run wires through
Picture inside the lid. The small lipo battery fits perfectly into this slot.
Tight fit, but I got everything in.
Toggles Switches (Bottom of lid view)
Finished Product
Runtime with (4) 11.1v, 5,000 mah batteries: 27 minutes
Major Components:
200W LED
- Epistar 200W, 32-34V, 7A, 20-22,000 Lumen, Color Temp: 4000-4500K
- Seller: Tiaochongyi (Ebay, 99.8% Positive Review)
- Price: $47.98
200W White High Power LED Optic Glass Lens Aluminum Reflector Fixed Mount Holder
- Seller: Top-LEDlight (Ebay, 99.0% Positive Review)
- Price: $19.99
Tollshop Plastic Ammo Box
- 5 1/8" x 11 1/2" x 7 1/8"
- Seller: Menards
- $4.95
Geeetech 150W Boost Converter DC-DC 10-32V to 12-35V Step Up Voltage Charger Module
- Seller: Amazon
- Price: $6.99
Mcshow Yaln FAN D50sh-12c Fan 50*50*20mm 12v 0.27a 2pins 2wires Cooling Fan
* Supplier: Amazon
* Price: $8.99
* Used to cool Geeetech Booster. Fits perfectly on top of Booster's heatsink. Zip tied it to the Booster
(5g) Thermal Conductive Heatsink Plaster Viscous Adhesive Compound Glue For PC GPU IC
- Seller: Amazon
- Price: $4.99
DEEPCOOL GAMMAXX 400 CPU Cooler Heatsink w/ 120mm PWM Fan w/ Blue LED
- Seller: Amazon
- Price: 29.49
Kingwin 120 x 120 mm Long Life Bearing Case Fan CF-012LB Black
- Seller: Amazon
- Price: $6.49
- Comments: Used as a spacer for the interior, between heat sink and case. I removed the fan component to allow air flow. I also had to trim off part of the side since the Ammobox is tapered.
ZIPPY Flightmax 5000mAh 3S1P 20C Battery – 4 Pcs
- Seller: HobbyKing
- Price: $21.82/ea
ZIPPY Flightmax 1000mAh 3S1P 25C 11.1V, 1 pcs
* Supplier: Amazon
* Price: 6.78
* Used to power both of the cooling fans
Battery Wiring Diagram
Floureon 2 Packs RC Lipo Battery Monitor Alarm Tester Checker Low Voltage Buzzer Alarm with LED Indicator for 1-8S Lipo LiFe LiMn Li-ion Battery - 2 Packs
* Seller: Amazon
* Price: $7.99/2 Pack
* Used to monitor battery level on Lipo's
HXT4mm w/12AWG Silicon Wire 10cm (ESC side) (5pcs/Bag)
- Seller: HobbyKing
- Price: $5.75
RadioShack SPST Rocker Switch (Neon), Catalog #: 2750692 – 2 Pcs
- Spec: 10A @ 125VAC or 6A @ 250VAC
- Seller: RadioShack
- Price: $5.00
- Note: Fits perfectly in the lid. They are also sunken so to speak, so it would be hard to accidentally turn on the light.
Misc Supplies:
- Wire
- Wire Nuts
- 3M Dual Lock Velcro – Holds battery to Ammo Box
- Zip Ties – Glued to Ammo Box and used to secure Boost Converter
Build Comments:
- Light has a switch for the light and a switch for the fan. After you turn off the LED light, I would continue running fan until it cools.
- Had to drill holes in heatsink for the wires to pass through
- Drilled holes on both sides of the Ammo Box to allow air flow
- You could install these on the side to filter air going into box
- Coolerguys 120mm 3 Part Fan Filter Grill with screws (2 Pack)
- Seller: Amazon
- Price: $10.64
Build Pics:
Cut out a hole in front of the case for heat sink cooler pipes to pass through.
Note: The hot part of the light is outside the case
Drilled holes in both sides of the case for air to pass through
Misc Pic (Coolmax component attached to heat sink plate from lens kit)
Drilled holes in the heat sink plate (lens kit) to run wires through
Picture inside the lid. The small lipo battery fits perfectly into this slot.
Tight fit, but I got everything in.
Toggles Switches (Bottom of lid view)
Finished Product
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