DIY Emergency Gadget: 50W LED Torch With Dual USB Power Bank

Do you have an old LED bulb lying around? Instead of throwing it away, let’s turn it into something useful! In this project, I’ll show you how to recycle an old LED bulb case and convert it into a 2-in-1 Power Bank and High-Power Torch.

This DIY gadget not only gives you a 25W/50W LED torch with adjustable brightness, but also works as a fast-charging power bank with dual USB outputs (Type-C + Micro-USB). You can charge your phone, headphones, or other small devices, and at the same time use it as a bright emergency light.

It’s compact, rechargeable, and a great way to reuse old parts while making something really practical.

1. Old LED bulb case (housing)
2. 25W or 50W High Power LED / COB LED
3. XL6009 Boost Converter Module (for LED drive / voltage step-up)
4. Power Bank Fast-Charging Module (with 2 USB outputs – Type-C + Micro USB)
5. 18650 Li-ion Battery Holder (3-cell parallel type)
6. 3× 18650 Li-ion batteries
7. On/Off switch
8. PWM dimmer (for LED brightness control)

1. First, take your old LED bulb.
2. To make opening easier, slightly heat the sides (you can use a hair dryer or heat gun on low).
3. Gently press and twist the diffuser (white cover), and it will pop open.
4. Once open, carefully remove the LED plate with its heat sink and the old driver circuit inside.
5. Now you’ll have an empty LED bulb shell, ready to be reused for your DIY torch + power bank project.

1. Take a 12V 25W or 50W High Power LED / COB LED.
2. Apply a thin layer of thermal paste on the backside of the LED for proper heat transfer.
3. Place the LED on the old bulb’s aluminum heat sink plate (backside of the LED board).
4. Drill two small holes on the plate, align the COB LED, and use screws to fix it tightly in place.
5. Now solder red wire to + (positive) and black wire to – (negative) terminals of the LED.
6. Make the wires come out to the backside of the heat sink for further connections.

1. On the backside of the COB LED’s heat sink, fix a spacer/stand-off to create some gap.
2. Place the XL6009 boost converter module on the spacer and screw it tightly.
3. This ensures the module stays firmly attached while leaving enough space for air circulation and safe wiring.
4. Keep the input/output pins of XL6009 easily accessible for connecting the LED and battery later.

1. Take your power bank fast-charging module (with dual USB ports).
2. On the board, you’ll see a small digital display soldered with a 5-pin connector.
3. Carefully desolder the display from the board.
4. Solder 5 wires (around 3 cm long) to the board’s display pins.

1. Take a piece of acrylic sheet (you can get it laser-cut at a local shop).
2. Design a small box enclosure as per the size of the power bank module.
3. Ask for cut-outs/holes in the acrylic for:
4. 
   
5. The USB ports
6. The digital display
7. The ON/OFF switch
8. 
   
9. Fix the power bank module and its extended display into the acrylic case using screws or glue.
10. Glue the acrylic pieces together to form a sturdy box.
11. For the switch connection:
12. 
    
13. Solder one wire from the +ve output of the power bank module to the switch.
14. Take another wire from the switch output to your circuit.
15. Connect a negative wire directly from the power bank module –ve terminal.

✅ Why I Chose PCBWay?

1. High-precision manufacturing
2. Fast delivery with worldwide shipping
3. Low cost (great for students, makers, and pros)
4. PCB Assembly service available
5. Excellent support and instant online quoting

🧾 Simple Ordering Steps:

1. Design your PCB in software (like KiCad, EasyEDA, or Eagle)
2. Export your Gerber files
3. Go to PCBWay.com
4. Upload your Gerber files
5. Get an instant quote and place your order

🚀 With PCBWay, your DIY project becomes more professional and reliable!

👉 Order your PCB now at PCBWay.com

1. Take the old LED bulb case and mark a square cutout the same size as your acrylic power bank box.
2. Carefully cut out the square section using a rotary tool or sharp cutter.
3. Use a small file to clean and smooth the edges for a proper fit.
4. Insert the acrylic power bank box into the hole.
5. Apply strong glue around the edges to fix it firmly in place.
6. Make sure the USB ports, display, and switch are properly aligned and visible from outside the bulb case.

1. Connect Power Bank to XL6009:
2. From the power bank module (switch wires), solder one wire to the +IN of XL6009 and the other to the –IN of XL6009.

1. Add PWM Controller:
2. Connect XL6009 OUT + to PWM controller +IN.
3. Connect XL6009 OUT – to PWM controller –IN.

1. Connect PWM to LED:
2. From the PWM controller, connect OUT + to the LED + (red wire).
3. Connect OUT – to the LED – (black wire).

1. Fixing the Potentiometer:
2. Use a screwdriver to tighten the PWM controller.
3. Place the PWM potentiometer knob on the backside of the LED case.
4. Remove the old bulb’s male cap, and fit the PWM pot shaft there.
5. Glue the pot in place and fix the knob for easy brightness control.
6. 
   

1. Take a 3-cell 18650 holder (parallel type) and place 3 × 18650 batteries inside.
2. Solder the –ve side (black wire) of the holder.
3. Solder the +ve side (red wire) of the holder.
4. Now connect the holder –ve wire to the power bank module –ve terminal.
5. Connect the holder +ve wire to the power bank module +ve terminal.
6. Double-check all connections to ensure correct polarity before powering ON.

1. After completing all wiring, turn ON the power bank switch.
2. Use a screwdriver to adjust the XL6009 output to 12V (check with multimeter).
3. Once the correct voltage is set, fix all modules (XL6009, PWM controller, battery holder, wiring) securely inside the LED bulb case with glue or screws.
4. Place the diffuser/LED cap back on the bulb case and close it properly.
5. Your Power Bank + High Power Torch is now fully ready.
6. Test the USB outputs for charging and turn ON the LED torch — adjust brightness with the knob.

1. You can charge the built-in batteries using Type-C or Micro-USB input on the power bank module.
2. You can also use the USB ports to charge your phone, headphones, or other gadgets.
3. When you turn ON the switch, the torch LED lights up.
4. Rotate the knob to increase or decrease brightness as needed.

That’s it — your DIY Power Bank + High Power Torch from an old LED bulb case is complete!

You can charge devices, adjust brightness, and use it as an emergency light.

👉 Watch the video and enjoy! 🎥✨