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DIY: XP series LEDs 90 gallon KillaB style

So after months of planning I finally took the dive into leds. I started to get sick of my electric bill for my MH and VHO setup. In total I was running 2x 175 watt halides and 220 watts in VHO over my 90 gallon. Great lighting setup, worked for 2 years wonderfully, but the constant running of my chiller to maintain temp added to the expense. I’m in an upstairs apartment and heat is always an issue.
I started looking for a group buy, as I knew this would be by far the cheapest way to obtain my leds. I found a thread on this forum for a group buy to Rapid LED. I ended up saving a significant amount by purchasing so I’m glad I waited for a group buy.
The final Purchase to Rapid LED was as follows.
1 – 48 Ultra premium kit - 24 Xpe Blue, 24 xpg cool white
1 – 12 Ultra premium kit – 12 Xpe Blue
4 Single xpg cool whites
1 Extra ELN-60-48P Driver
All with 60 degree lens
All with ELN – 60 -48p drivers to later dim with Aduino Based controller
2 Y shaped hanging kits
2 10v Adaptors
All thermal Grease as well
In total 64 Lens, 36 Royal blue 28 Cool white. My design was to make 2 separate pendants for my 90gallon, 32 leds per pendant.
So I got started with 20ft length 1x1 Aluminum (because it was free lol). The goal was to make inexpensive heatsinks from them. The same person I got the aliuminum from was able to weld it for me as well. Welding was done with a mig welder with spool gun. This saved me a lot because I was considering buying
<img src="http://img823.imageshack.us/img823/3818/74477439.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Didn’t look great after the welding, but a little grinding would clean it right up.
<img src="http://img820.imageshack.us/img820/4518/26871912.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21

Next was to figure out my Layout. In the initial ordering I knew I wanted more blues then whites. For those of you that don’t know it’s because the XPG whites are more powerful then the XPE blues. So to get a 1:1 ratio you need to have more blue then white. After playing around with the LEDs on the heatsinks for a couple days I finally figured out a layout that worked for me.
<img src="http://img9.imageshack.us/img9/6884/layoutus.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I decided early on I wanted to to be able to remove the leds so I opted for the thermal grease vs thermal adhesive. I planned to rivet each led using 1/8 rivets and clear nylon washers.
<img src="http://img196.imageshack.us/img196/3686/52300480.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img146.imageshack.us/img146/2889/82386212.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
After tracing the Leds locations out I began drilling and riveting. I did the whites first and followed with the blues.
<img src="http://img854.imageshack.us/img854/2047/28573120.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img11.imageshack.us/img11/2061/38860407.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I wanted the wiring to be as neat as possible so I alternated the leds in each row + facing up then the next – facing up and so on and so forth. This would make the wiring go straight across vs on a diagonal.
<img src="http://img580.imageshack.us/img580/5686/24824500.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I made the housings for the heatsink out of craft board found a lowes. Its 3/8” by 3” for the outsides and 3/8” by 4” for the length. The 4” side will hold the splash shields.
I began by using my table saw to cut the groove for the splash shields in the 4” boards.
<img src="http://img21.imageshack.us/img21/6008/89571364.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Began assembly rather quickly , and didn’t get a chance to take pics of the actual process, but you get the idea.
<img src="http://img692.imageshack.us/img692/2226/56713313.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
At the corners they are secured with 1 inch brads. After sanding the enclosures I sprayed them with a rubberized coating the protected them from humidity/ Reef elements.
I installed the Heatsinks into the enclosures, and riveted them into place with black finishing rivets. You can see clearly in this pic.
<img src="http://img11.imageshack.us/img11/8241/65290049.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
With the mounting all buttoned up I turned the units over and drilled and installed the bolts/studs that will hold the lids on.
<img src="http://img51.imageshack.us/img51/9503/13649881.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I then Installed my barrier strips for wiring the LEDs, Fan, and power for 12v 10v and 110v. The left is to be used for LEDs, 12v for fan, 10v for dimming. The right will be for 110v power.
<img src="http://img842.imageshack.us/img842/4705/29640029.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I drilled through the heatsinks for each led array to be wired. I installed rubber grommets on the front side to insolate the wire from the aluminum.
<img src="http://img215.imageshack.us/img215/6190/84086311.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I decided to install fuses in line to protect the circuits. This will also double as a location to set amperage on the drivers.
<img src="http://img11.imageshack.us/img11/3229/25935074.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I began wiring each string of leds to the barrier strip. There will be 3 strings of Leds on each pendant. 2 Blues and 1 White. All running on 3 separate drivers.
<img src="http://img30.imageshack.us/img30/9264/58873700.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I striped the wires on each driver and installed them into the enclosures
<img src="http://img155.imageshack.us/img155/5420/99129776.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Unfortunately the final pictures of wiring were lost But I did manage to take a final picture of the complete wiring.
<img src="http://img824.imageshack.us/img824/9506/56547071.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Both units all finished up
<img src="http://img21.imageshack.us/img21/6373/27805616.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I set the amperage on each unit with a 10amp volt meter. Blues set to 750mah the whites set to 1000mah
And let there be light!
<img src="http://img195.imageshack.us/img195/6124/98990256.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Now it was time to fabricate the lids from plexiglass. Each lid will have a cooling fan installed and will pull fresh air through the unit to cool the heatsinks and drivers.
¼ -plexi was used for this, 80mm holes were drilled in the center of each. Holes for hangers and lid mounting bolts would be drilled as well.
<img src="http://img96.imageshack.us/img96/9390/53212063.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I decided to tint the lids, I thought it might ass to the sleek look I was going for.
I used a spray tint found at pepboys, its used to tint taillights on cars. I gave each lid a light coat and then clear coated each.
<img src="http://img233.imageshack.us/img233/7056/87166726.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
After clear
<img src="http://img818.imageshack.us/img818/3428/11717313.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I but a foam gasket material around the mounting surface of the pexiglass lid. This was to help seal the unit so air will be pulled in from the bottom.
<img src="http://img190.imageshack.us/img190/962/36730945.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I installed the fans with chrome grills as well as the hangers.
<img src="http://img37.imageshack.us/img37/7362/10711570.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Almost done!
<img src="http://img88.imageshack.us/img88/3958/23562105.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Each unit was then turned over to have the 60 degree lenses epoxied to the leds.
<img src="http://img832.imageshack.us/img832/8309/76812494.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img546.imageshack.us/img546/358/18106748.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21

Final product!
<img src="http://img11.imageshack.us/img11/8241/65290049.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img577.imageshack.us/img577/7342/45209493.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21

I hung the pendants with 2 eye hooks to the ceiling and 2 locks for each. I didn’t have any studs to drill into so I used toggle bolts anchors.
<img src="http://img684.imageshack.us/img684/2742/40613883.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img843.imageshack.us/img843/7480/24269376.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img607.imageshack.us/img607/5041/31054016.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Here’s a shot of the hangers installed to the locks. These will hook to the eyehooks in the ceiling.
<img src="http://img269.imageshack.us/img269/6189/57508803.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
I hung the pendants higher then the old lights location to prevent burning of the coral because I don’t have my dimmer setup yet. This is how it sits currently, I needless to say I’ve impressed myself lol. It shows how far good planning can go!
<img src="http://img402.imageshack.us/img402/527/97799897.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img220.imageshack.us/img220/9435/imag0477n.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
<img src="http://img600.imageshack.us/img600/2962/imag0476d.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
Heres a view of the top sides, each unit has 2 power cords. One for blue and one for whites, this is a semi-temporary solution till I build my dimmer
Before w/ 2x 175watt 14k iwaski, 2x 110watt vho uri:
<img src="http://img845.imageshack.us/img845/2829/70510468.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21
After w/ 64 Xp Leds. 14 XPG Royal Blue - 18 XPE Cool white per side:
<img src="http://img34.imageshack.us/img34/8806/23156032.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/killab443">killab443</a> at 2011-07-21

Note That these Led pendants are still brighter and they are not at the final height yet. They will come down another 6 inches over the next month
 
$580 for Leds, drivers, dc adaptors, and hangers. Wire was free from bad old computer power supplys I saved. Trips to radioshack about $50-$60 for all the terminals and watnot. Plexi I had from my sump build. But thad be another $40-$50. The wood for the enclosures was around $20. Rivets and washers were $15. Hanger hooks, eye hooks and misc stuff was another $40-$50 from lowes. All in all Probably around $750 not including Heatsinks. But if you want to buy 1x1 20ft length is around 25$ from a metal supply, you just need to find someone to weld it.
 

malulu

NJRC Member
i noticed a lots of LED fixtures on the market used two fans, may be that is for a fail safe backup purpose? may be you wanted to install one extra fan too?

you build look very professional! thank you for sharing...
 
Looks like you did a great job on the build. The LED fixture I have is a 300 watt unit and it has 6 fans. I guess I got a good deal on it considering the cost of your supplies.
 

Fish Brain

Officer Emeritus
Officer Emeritus
Build looks good but from a engineering/structural stand point, I would mount the hanging kit from the frame/heatsink or add additional screws to the lids. Having only two mounting points in the lid, supporting the entire weight of the fixture, is going to result in a cracked lid and possible light fixture in the tank. :( Pressure = force / area, you are putting a large force(entire weight of the fixture) in a small area (2 mounting points) and that could result in structural failure of the plastic lids. I can already see the plastic sagging under the weight in the first picture of the lights mounted over the tank.
 
I think your seeing things because its right in front of me and its definitely not sagging. The light doesn't weigh 30 lbs, it weighs about 10lbs. 1/4 plexi isnt going to crack with less the 5 lbs of pressure in 2 seperate areas.
 
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