750w to 1500w Work Light Mod

Here we go! The 750 to 1500 watt work light mod. You will want to be extra careful with this one, since it uses so much power and takes a bit more wiring.

So here is a shot of everything I used for this project, and in a list:

•  Screwdriver set
• Soldering gun
• husky brand (home depot) 750w work lights (it uses 2 bulbs)
• 25 ft 14 gauge extension cord
• home made U bracket (pictured later)
• pliers
• scissors

So now it's time to take the whole light apart. Completely gut the thing. It's a good idea to get a piece of paper and record which bolts are for what so you can put it back together when you're done.

It should look like this now:

You see that box on the back with the buttons on it? Unscrew that and take it apart. Take all the wires out of it, the only one you will need is the end part of the green one, 3" or so. You see that nice bracket in there holding the power cable in the box? Keep that for later.

Cut that green wire and strip it down. Now take your nice extension cord and cut the end off that does NOT plug into the wall. Strip the orange back about 1 foot (enough to run all the into the light). Oh look! A green wire. Connect them with solder. Now run all the cables through that black box like this:

Now you can feed those black and white wires into the light fixture and attach that green one back to the outside of the fixture.

Time for the bracket. The bulb is 6.5" long, so the bracket should measure 5" to accommodate the R7s connectors on the ends. This is the hardest part because you need to get the order of connecting the pieces in the right order. Proper order:

1. Solder wires to r7s contacts
2. Assemble bracket
1. You may need some of your own hardware to do this. It's easy to figure out though.
3. Put bracket in fixture

It should look like this:

Now you just need to get the reflector in. Use the scissors to cut the metal to fit into the housing. You may need to find more metal to go behind the bulb for better efficiency.

NOTICE: Make sure the wires that are behind the reflector are as far away as possible from the bulb. The first time I did this the light exploded and a wire burned through some metal. Heat shield everything as much a possible. Also, wiring a switch didn't work out yet. I need to rewire it and I will post and update when that gets done.

Plug it in and enjoy your 42,000 lumens!

Next up: Make a TVMP Adapter for $1.73 (lightstand adapter)