Halogen Work Light Projector Mod V2.0

Out Dated Mod:

The projector mods I did are out dated at this time. There are projectors with much better optics, brightness and throw distances. If you looking for a long use projector, with inexpensive bulbs, like I was when doing this mod, I would suggest getting an LED based projector. They provide superior brightness, rich colors, and most of all ridiculous long life spans over using a bulb based projector. Most of all there very inexpensive. Seriously Check out Amazon for LED Projectors. Just remember to find the Native Resolution, Brightness, Inputs and check the user reviews before making your purchase.

Considering what you can get NEW and at a reasonable price, modding is just not worth it.

A Home Theater that won't brake the bank.

Simply use a burnt out projector and a Work Light from Home Depot and bring the theater home!

The OEM replacement bulb for my projector cost $300 (!) , more than what I paid for the projector it self. Also, my power supply that powered the original bulb was almost toast. Using this guide, you can use a Halogen Work Light bulb for about $10 dollars.

If you like this mod please Digg It!

This project is a redo of my Automotive Head Light Projector Mod

WARNING: This mod involves modification of a projector, electrical wires, switches and a high power bulb. If you are not comfortable with modding on this level, DO NOT attempt this mod. The writer is not responsible for any injuries or damages resulting from these instructions.

Obtaining the Work Light

'Step 1: Go to HOME DEPOT'
In their Electrical Section you will find a small ~$10 250 Watt Halogen Work Light
Make sure that the bulb is 3.15 inches NOT a 4.69 inch or it may not fit.
You will want to measure the space that you have in your projector before going to the store.

You can get 3.15 inch bulbs that go from 75 to 400 watts in 3.15 inch. However, remember that even though more watts means more lumens, it also means more heat.
(We don't want to melt the projector or start a fire)

Once you have found the bulb that will fit your projector, Buy it and continue to step 2. ------->

Taking Things Apart : )

Now that we have the work light take it apart!
The nice thing about the work light is that it contains all the things we need to build this mod. A halogen bulb, a bulb socket, switch, and a power cord. The only thing you need are tools (a screwdriver, pliers, drill & bits) and wire nuts.

Disassembly is easy, as the light comes only partially assembled.
All screws used a Phillips driver, and to remove the clear wire nut crimps just pinch them on the sides with some pliers.

There are four parts we will need. The Halogen Bulb, the Bulb socket, switch, and power cord.

Put the light casing back in the box for your next project.

Mounting the Switch

Drill a hole in your projector where you have room for the switch, wire and nuts underneath.
On my projector about 2 inches from the bulb socket worked well.

Unscrew the red switch and mount it in the casing. (See picture)

Add POWER!

Drill another hole for the power cord. Push the power cord through the hole and secure it with a zip tie.

Wire the Switch and the Bulb Socket.

Wire the switch, power cord and bulb socket. You should know that in building wiring Black = Hot, White = Neutral, and Green = Ground.

Wire the switch through the hot wire, and the bulb socket white to white and black to the switch. You can ground the Green to the ground on your projector.

If you don't know electrical wiring I suggest getting a friend to help with this project.

Insert the Bulb and Reassemble the Projector.

Place the bulb in the bulb socket and place it directly where your original bulb would be or your automotive head light was if you completed my previous mod.

It's SHOWTIME!

After checking all your electrical connections, Fire up your projector. Make any adjustments to the bulb placement if needed after the bulb has cooled. I can get a massive 12 Foot screen using this mod. Its much brighter than the automotive light I used last time.

Invite your friends over to the movies and show them the projector you modded.
Pop popcorn and through in one of your favorite movies.

Please check out my other projects:

Automotive Head Light Projector Mod
Upgrade from VISTA to XP

CAUTION : This Halogen bulb is MUCH HOTTER that the automotive headlight that was used last time.
You will need a significant amount of air flow through the bulb chamber to cool the bulb and NOT START A FIRE! Also, keep the bulbs power cord unplugged, you don't want someone turning on the bulb with out the fan. I am not held responsible for damages due to improper use of your projector.

My next project how to make perfect popcorn!
This popcorn popper makes great popcorn. Legend has it it was discovered abandoned in a work camp on the Alaskan pipeline.