Life, photography and philosophy at 1:87 scale…

Life, photography and philosophy at 1:87 scale…

Life, photography and philosophy at 1:87 scale…

’Tis the Season for New LED Headlights

LED lights offer a number of advantages over traditional incandescent lights for your locomotive projects. They are significantly cooler, have an extremely long life, and offer a higher degree of light consistency from bulb to bulb. These advantages make them ideal for engine lights, and have become a staple of my engine maintenance- particularly for my Athearn engines. For some reason Athearn uses incandescent grain-of-rice (GOR) bulbs that are both too small for the light opening and are extremely short lived. Other manufacturers use LED’s, but rely on “light pipes” to direct the light, which results in reduced brightness and inconsistency. Using LED’s solves these problems, however a little work is needed to get them to fit in your model. The next few pages will show you a quick-and-dirty way to make LED’s ready to go.

A box of “warm white” LED Christmas lights I bought at Target for $7.00. There were 62 individual bulbs in the box, so the cost was just over 11¢ each. Not a bad price considering everything.

The LED Christmas lights as the come out of the box.

62 LED’s and their sockets once removed from the wires.These are a standard 5mm (T 1 3/4) size, although they lack the lower “lip around the bottom.

The LED’s without their sockets. 5mm LED’s work better than 3mm LED’s since there is more material between the lead frame and the tip. This give you more options when installing.

The LED on the left is from the Christmas lights, the one on the right is a standard bulb. You can see the missing “lip” around the one on the left- this comes in handy during the next step of the process.

Here I’ve trimmed the anode and cathode down to allow for easier insertion of the LED into my drill for machining.

The LED has been set in the chuck of my cordless drill. I know it’s not very elegant, but it gets the job done and I don’t own a mini lathe.

It’s somewhat hard to see, but make sure that the leadframe (the part inside the LED that produces the light) is set far enough back that it doesn’t protrude. You don’t want to be able to see it.

I start my drill running and move a file back and forth to start removing material. You need to use firm pressure, but not too much you break it.

As the process moves forward, you’ll start to generate a lot of white dust. Be sure to keep the file at a 90º angle to the face of the chuck and parallel to the LED.

The LED lens is getting thinner. Be extra careful at this point not to push too hard with your file or you’ll snap the LED in half.

When you think you’re getting close, start checking the size of the LED lens. For this application I’m shooting for 0.070 of an inch, which is equivalent to a #50 drill bit.

The LED has finally been machined down to size. You’ll find that not all engines have the same sized openings for headlights. I’ve seen models range from 1.5mm to 1.8mm, so be sure to check.

A reduced LED. It’s still plenty bright and will fit snuggly into the existing headlight opening if you need a single bulb headlight you could be done, but more work is needed for a double headlight.

A side by side of a warm white and a cool white LED. Your choice of which to use will vary depending on application and personal preference.

For a double-light application the lower sides of the LED have to be sanded down. This allows the LED’s to sit closer to each other. For this I used a cutoff wheel on my Dremel too.

Use care not to get too close to the leadframe or any other internal parts of the LED.

The final product.

A double headlight installation on the rear of an Athearn Genesis F45. This is a big improvement over the original undersides and short-lived incandescent bulb.

Here I’ve just installed a single LED in the upper headlight opening on my F45. The light fits snuggly, but can still be removed if necessary.

The new LED headlights in action. they are plenty bright, run cool and won’t burn out anytime soon.

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