An Improved Work Light For The Mini Mill

For some time I’ve used Ikea JANSJO gooseneck lamps around the workshop. They’re great, but they’re not totally without shortcomings. In this film I build an alternative work light for my milling machine.
I examine what makes the JANSJO lights tick, and find out what’s under the bonnet of some low cost automotive LED ring lights (and learn a bit about the PT4115 and TP8005 LED driver), and modify them to suit my needs. Once relatively uncommon, these rings are now readily available from all the usual on-line suppliers (also variously referred to as DRL rings, AngelEyes, Halo Lights, COB rings, etc).
This build started way back in 2016, before having the misfortune of becoming one of my many ‘paused projects’. It resurfaced almost a year ago, and has been on the back burner ever since, creeping along bit by bit as-and-when I had a few minutes to spare. This film contains (amongst other things): turning, milling, drilling, anodising, annealing, electronics, CAD and how not to make a face grooving tool 😉
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I’ve had a couple of viewers ask about the plug and socket I used between the die cast box and wall wart power supply: They’re Binder 719 series circular connectors. Over the years I’ve used them for a number of projects and found them to be both versatile and reliable (coming in male / female / cable end / panel mount varieties and in 3, 4 and 5 pole). They’re a little bit expensive for my budget (though not in the same league as the all metal connectors from the likes of Lemo and Fischer) but being solder bucket you can offset the cost a little by not needing special crimp or pin insertion tooling.
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I’ve had a number of comments suggesting this build may have been completed using 3D printer.
Take a look here: • LED Spindle Light: 3D ... for a little more info on why I completed the build the way I did.
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A quick shout out to @JimTaylor42 whose Design Spark Mechanical series have managed to drag me from strictly back of an envelope to an occasional (but still not yet very proficient) CAD user.
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All imperial conversions are at best approximate, and are just for the benefit of anyone not viewing in metric 😉
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Chapters:
00:00 - Jansjo lights: The good
00:16 - Jansjo lights: What’s inside?
00:31 - Jansjo lights: The not so good
00:53 - Planning an alternative light source
01:40 - So many projects, so little time
01:55 - A change of plan
03:00 - Starting the build
03:53 - Adding some detail
04:14 - An experimental grooving tool
05:10 - Perseverance over planning
05:27 - Adding more features on the lathe
06:49 - A little coordinate drilling
07:23 - Modifying button head screws to suit
08:21 - Planning LED fitment
08:56 - Prototyping the wiring
09:48 - Machining a brass saddle
11:37 - From machining to electronics
12:08 - TP8005 versus PT4115
12:47 - Ring light driver circuit tests
13:29 - Adding a brightness control
14:06 - Here’s one I prepared earlier
14:28 - Bending thin walled brass tube
15:13 - Anodising aluminium
16:33 - Starting assembly
18:48 - It works!
19:02 - A side project from left overs
19:16 - Jansjo lights: Change to survive
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For the material I couldn't capture myself, my thanks goes to the following:
Evan at time.is/ for kind permission to use calendar screen grabs.
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Mike from AutoPhotography for the use of the BMW headlight, via pixabay.com/
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Blastwave FX for the slap sound by via www.zapsplat.com
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Manually subtitled for accuracy -click the CC box.
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Shot: HDC-HS700 1920x1080 50P AVCHD
Edit: DavInci Resolve 18 ProRes 422
Mic: DR-05

[@TheRecreationalMachinist]

Thanks for all the comments! To those suggesting this job might be better suited to a 3D print, take a look at this short update: kzbin.info/www/bejne/jmXGpZqQgNRkbsk

[@thebooduck]

"…back in 2016, when this project started…" this is too relatable 🙃

[@InheritanceMachining]

What a nice, clean build! I especially like how you got into other details besides just machining, like the circuit re-design and anodizing, to get it just how you want. Really neat. This is also my first time watching (not sure why) but your editing and voiceovers are great!

[@toteu00000]

My first time watching too! It instantly reminded me of your channel.

[@charlvanniekerk8009]

Good to see you here !! Unbelievably its my first time too!

[@mobilisinmobili4836]

i sense even more side projects in your videos now :D Love your channel btw

[@TheRecreationalMachinist]

Thanks for dropping by @InheritanceMachining! If I'm ever half the machinist or film maker you are, I'll be very pleased indeed 👍 🇬🇧

[@InheritanceMachining]

@@TheRecreationalMachinist You are very kind... but I have a lot to learn yet. That's the beauty of this trade!

[@janosnagyj.9540]

Man, I really love your content: the quality of filming, editing, your calm voice, and the interesting job itself: everything! All first class!

[@1123pawel]

Agree 100%

[@Watchyn_Yarwood]

@@1123pawel Indeed! I could listen to him talk for hours!

[@bencrosskey3241]

Agree. Add some soft instrumental synth-pop and this could How It's Made.

[@Robc509]

Yes wanted to write something similar but you wrote it much better than I could of

[@DrZipZwan]

@@bencrosskey3241 wachted some others of his video with some kind of piano back sound, a pur regale

[@jessefoulk]

His voice would be perfect for a children's book story telling. Golden.

[@pixels6989]

Thanks to your video, I am learning more everyday about machines.

[@Kbutt]

Instead of just slapping the light on dude started to do rocket science. I LOVE IT😀 very good video and you got a new sub🙂

[@hawkie333]

"Fast forward 6 years"…love it!

[@kentuckytrapper780]

Nobody can ever say you half ass a project, great job, great video, keep'um coming..

[@kennypinkerton5818]

Setting up the milling machine to anything you think is precise... is the ultimate time machine.

[@TrevorDennis100]

I'm watching this process and thinking back a zillion years when I have a UK VHF Amateur Radio license (I was G6HVK). I spent some time and a lot of effort into making a 12 element Yagi antenna, and on completing it, spoke to someone in Holland, and never used it again. To be fair, the normal conversation in such communications is a bit boring - this is what I am using, this is your signal strength - so I went back to chatting to my mates on the repeaters till I got bored with that and found another hobby to obsess about. All these years later, nothing has changed. When people ask what I make in my workshop, I am a bit embarrassed to tell them that, for the most part, I make things 'for' the workshop rather than with the workshop. So I completely understand your putting so much effort into your machine light. And a jolly nice job you have made of it.

[@TheRecreationalMachinist]

Don't be embarrassed! From what I've seen we're not alone! There's plenty of us who don't have an overarching reason to make things, but really enjoy the process and so keep doing it. For me, pottering in the garage led directly to a new side hobby, making short films for KZbin. Thanks for watching 👍 🇬🇧

[@rocksolidhugo]

Outstanding material. The content, the filming, the editing, the narrative... Subscribed

[@ramonching7772]

Paused for 6 years. I can really relate to that. 😊😊😊😊😊

[@pixels6989]

As always very interesting video. 👍

[@marceloiannini8199]

God! If some parts of your build are half decent, than all of mine’s are 1/1000th decent! Congrats for your dedication

[@Pushyhog]

lights action camera editing timing filmography , spot on.

[@1123pawel]

You too have biscuit tins with paused projects.... Thank you for this very enjoyable video. Great finished product.

[@lbgstzockt8493]

This video is superb, the light came out really nice! I would totally buy one if I owned a mill.

[@MgBaggg]

Art, the work, the craftsmanship, the video, the results

[@HaxbyShed]

Technically excellent, visually excellent. Just excellently excellent. Just on another level. 😁 Cheers

[@TheRecreationalMachinist]

Thanks Paul! Good to have you along 👍 🇬🇧

[@k9elli]

I have a bunch of mid 2010 projects I’m still working on. No need to remind me every 6 months, I’ll get around to it 👌🏼

[@eatenkate]

You've just got such a nice and calming voice, every video turns into a machining fairy tale (:

[@allthegearnoidea6752]

My paused project space currently occupies a double garage. Yet another beautiful video from you

[@12345NoNamesLeft]

0:50 Perfect shot, great side by side comparison of light temperature/colour

[@ambisinisterengineering5242]

Elegant solutions to problems really nice work as always

[@sophakpeth4346]

I’ve never seen something so simple yet complicated at the same time. Well done!

[@wilhelmloof8752]

Impressive and elegant! You are living the dream with that workshop and knowledge.

[@Preso58]

Nice job. You may want to check the pH of your black dye. Mine wasn't creating a deep black. It was a sort of green grey. The pH should be around 6.5 and mine was about 8! A few drops of hydrochloric acid bought it back into range and now it works beautifully.

[@TheRecreationalMachinist]

Thanks for the tip. I'll bare that in mind for the next job 👍 🇬🇧

[@leec2106]

I do like what did, I will be adding a ring light to my Harbor freight mill, thank you for the idea.

[@jw200]

Excellent video. I can only imagine how much work and time it took to make it. Like and Big Thanks

[@TheRecreationalMachinist]

Sometimes it turns into a labour of love 😂 Thanks for your kind words.

[@jw200]

@@TheRecreationalMachinist lol. You're welcome 🙂

[@myharris]

Really like those jigs to work the bolts - not seen that before. I know now from previous videos of yours to keep a notepad handy while I'm watching! Thanks.

[@mrimmortal1579]

I’m not sure why the algorithm never brought me to your channel before. But I’m here now, and that’s what is important, right? Seriously though, this was my first time watching your channel. I hit subscribe as soon as it was over. You seem to be the Jack-of-all-trades type, and I like that. I also enjoyed your content and editing, and the lack of loud annoying background music. Looking forward to your upcoming projects (and also to bingeing your archive)!

[@davidsabbagh6815]

Man, that was a hardcore project. No wonder you waited so many years to finish it.

[@DavidHerscher]

Dang, nice editing, special effects and everything!

[@charlvanniekerk8009]

An incredibly clean build! I must say I am a bit shocked that its my first time watching one of your videos as their quality are amazing. Thank you for sharing

[@MyLilMule]

Brilliantly made. That was a lot of work. Very much the craftsman.

[@nitsan]

Wonderfully over engineered. I like it.

[@goldcoasttime]

BEST YET, This is the best spindle light I have seen, I have 2x Haas VM3's and a Tormach, If you build them I will buy, Try to make them locally, if its too expensive go offshore but assemble them yourself........................

[@gardnep]

Well done, an enjoyable vlog of many techniques that would have taken hours to make and edit. Thanks.

[@ashesman1]

So satisfying when you build something and it finishes up looking like it was meant to be there’s all along. Really nice work.

[@DudleyToolwright]

Beautiful work, with a nice attention to detail. I loved the creative presentation.

[@mikoro88]

You've got some serious skills for a recreational machinist! Very clean!

[@CTXSLPR]

All Hail the Algorithm for bringing me here for this! I’ve been toying around with ideas for how to do the same thing for my RF-31 since it’s down for a rebuild. Neat trick with the headlight ring.

[@faresalgahtani8745]

You maybe a recreational mechanic, but I really believe you actually make spaceships. You’ve got an incredible range of well honed skills!

[@rawbacon]

Have to keep that in mind if I ever need to bend some tiny brass tubing.

[@jamesinc87]

I'm glad I'm not the only one who stores projects in biscuit tins

[@eriks6693]

I really the 3D cad mixed with reality shots, well done. I have my guesses it would be cool to see how you did that

[@videogalore]

Just found the channel, really enjoyed that (we're a sad lot aren't we!). The camera work and details are fantastic - looking forward to delving through the other videos you have here.

[@snowgorilla9789]

And many watching are wondering how we have gotten along with a cheap magnetic flashlight. Great job/s

[@jimbrideau5802]

Exceptional detail to quality!

[@pendefig]

PCboard folks call the break away tabs that you were concerned about "Mouse Bites" usually the holes are unplated, bu if there are no other unplated holes in the assembly, they could save a process step by allowing them to be plated. I would not expect that they would be connected to anything, live, since when the part is broken out of the panel, the plated through holes could cause the plane layers to tear.

[@TheRecreationalMachinist]

That's really interesting -thanks!

[@SeanBZA]

They would be plated as that is cheaper, no need to run the board through with another drill file to drill them again, saving time on the stack of panels. Then the completed boards are milled before being snapped apart, and likely there are a series of these done all at the same time, to use the otherwise unused area inside, with the inner section going to make small lamp PCB units. After all the light PCB is made by another company, and they want to use as much of the board as possible, so will fit hundreds of jobs in the area of the board, with each likely having plated holes, so all will have plated holes, except the final step of milling out all the sections, so they can be depanelised when finished, sorted into each job, and bagged for shipping.

[@cyberlizardcouk]

beautifully over-engineered. love it.

[@nweston5070]

Love what you made there! I’d have gone straight to the 3D printer to make the housing but yours is far classier… I wonder whether, with a macro lens and your small and large rings, could you do a macro photography setup with bright field and dark field illumination options?

[@TheRecreationalMachinist]

I hope to dip my toe in the world of 3D printing sometime in 2023. Though my record for finishing projects on time isn't all that good! Thanks for watching! 👍 🇬🇧

[@fliprim]

So many good and interesting processes and ideas. Yep, this was bonkers over the top attention to detail to get shadow free lighting, but boy this was so full of insights. I love the mistakes that are learning moments. Over the top but nothing is wasted in this educational piece. Stunning quality productions. Thank you.

[@TheRecreationalMachinist]

Thanks for taking the time to watch 👍 🇬🇧

[@bikefarmtaiwan1800]

Looks like you deserve even better machines in your shop ;)

[@troy_neilson]

Seriously good job mate. The brass tube is pure class on an already fantastic project!

[@DavidLindes]

Right? Everything else was... something I hadn't necessarily thought of, but seemed straightforward/obvious enough. The brass tube, though, I would certainly not have thought of... though now perhaps I will! I love it!

[@andrewdoherty8847]

You were served up and the title caught my mind. I have just spent 2 days modifying a trailer hitch on the mill. The lighting is behind the tooling. My bandsaw has a light on flex which is also a pain. Do I want new lights? Too right. As I watched I realized what a quality production you offer. Nicely paced, lovely vocals and lighting, informative. A pleasant change from our usual stateside comrades. I subscribed. Re tube bending. Filling it with sugar is a nice twist on the other suggestions. You can dissolve it if need be.

[@NiksSofa]

The through hole vias are called "mouse bite". they are put in the tab where the cut out part is still connected to the larger panel during production. They make it possible to (mostly) cleanly break the part out of the panel instead of having to cut it.

[@Sembazuru]

My guess as to why there were residual hole plating in the mouse bites is often for cost cutting reasons some board houses plate all holes instead of having a mix of PTH (plated through hole) and NPTH (non-plated through hole). If you drill all your holes at the beginning before plating the holes that need it then you don't need to have drill bits in your milling machine when milling the profiles for final board shape as the final board shape. Makes for a less expensive milling machine for the final step if it only ever needs one tool instead of having a tool changer to swap between the single size milling bit and a variety of differently sized drill bits.

[@AlexNZL]

@Christopher Elliott they were probably used for testing. They leave them in the panel and then test the whole panel at once.

[@billmacfarlane4083]

Brilliant job...I wish I had your steady hands!

[@Ukenick]

Great video. Great pace, so clear and lovely voiceover. Also really nice work.

[@TheRecreationalMachinist]

Thanks for dropping by 👍 🇬🇧

[@arthurdent8091]

A masterful build thorougly performed. Kuodoes.

[@pjofurey6239]

Skills, and I,m comfortably reassured now I know there is not just me with paused projects and years between progress. Well filmed & narrated.HUZZAH

[@jonbruford7950]

I got myself a cheap USB ring light from ebay for about a fiver, zip ties onto a bracket that holds the depth stop (and poor mans DRO) on my chester eagle 25. 360 degree lighting in a couple of minutes. brilliant :-)

[@point775volts]

Top notch work through and through!

[@roylucas1027]

Great video. I’ve always wanted to fit a ring onto my spindle. It’s on my actual project list now. thank you for the inspiration.

[@joell439]

Stunning and extremely inspiring 👍👍😎👍👍

[@ladanleghae8938]

you are master of masters of work .. i wish you be my master

[@user-cr4sc1ht9t]

One trick I've seen in watercooling community for bending pipes without kinking was to insert a non-compressible but flexible material, e.g. silicone rod in case with clear plastic tubes. Apparently that works.

[@rallymax2]

Beautiful work. Beautiful production quality.

[@samb8414]

This video was so brilliant!!! Thanks for sharing ☺️☺️ I learned so much and suspect I will learn much more from you

[@edpopelas2844]

👍👍

[@willaiml]

Great craftsmanship

[@lumotroph]

Wow! So many amazing machining channels these days. Top notch 😊 subscribed

[@BrilliantDesignOnline]

WAY overkill, stupendous workmanship, a number of disciplines from which I learned quite a few things, great camera work and editing, and narration, and tea making 🙂 When I made the same thing for my 6040 CNC, I used blue foam (My first 3D CNC milling job) and double sided adhesive tape; having a 3D printer now, it would have been straight into SolidWorks, and then 3D printed. But you can be proud of your finished product and its incredible build quality. For my manual mill and manual lathe, drill press and 3D printer, I have found the 30 LED magnetic sewing machine light on a 200mm gooseneck from Amazon for $10 is very flexible, positional and BRIGHT and is the cat's meow.

[@TheRecreationalMachinist]

I hope to dip my toe in the world of 3D printing sometime in 2023. Though my record for finishing projects on time isn't all that good! Thanks for watching! 👍 🇬🇧

[@BrilliantDesignOnline]

@@TheRecreationalMachinist Might I recommend a Creality Ender 3 V2; now my second printer from a very rudimentary unit, and it prints perfectly and reliably right from the start (you do have to assemble it, but very simple, just make sure to adjust it properly; holds adjustment well). WELL worth the price.

[@TheRecreationalMachinist]

That's the model I was leaning towards, though I've some more research to do before I commit. Thanks for sharing your experience.

[@steejans]

Super awesome video! I might do the same for my little mill!

[@bps3374]

Nice work. Nice idea with brass Block & pipe for the Cable. Nice Transmission. Greetz from 🇩🇪 with now Abo 👍

[@kennethtencza9209]

Very clean and professional

[@jjbarrow8585]

Wow. Great idea, and very cool execution. Thank You.

[@makingwithsteve]

Found your channel just recently and couldn't help but to watch your entire library within a few days. Love your stuff and hope you keep making more!

[@anands6127]

Machinist with a good knowledge of electronics, superb

[@plunder1956]

Such an interesting & curious project I must check out more of your ideas.

[@davidgillies620]

The light housing looks like a stock part. Very nice job. I don't know what the obsession is in the UK with replicating gas lamps with LEDs, but finding 6500K lightbulbs in the supermarket or even a hardware shop is a nightmare. The CRI of warm whites is execrable.

[@niallsommerville9941]

Lovely professional job as always, much better than "bang 'em out" uploads, the devil is always in the very thoughtfully provided detail, thank you. Could you add an affiliate link for the PAUSED PROJECTS stickers, I could do with a few.

[@maxximumb]

This is the first of your videos I've watched. I'm very glad KZbin suggested it. Off to watch more as this one was excellent.

[@ScottDube1]

Brilliant! I really want to work on this anodizing process!

[@mp6756]

I enjoyed your video you should have ground yourself a trepanning tool. It affords much more support to the tool below center by following the radius as seen from the workpiece. You could grind a more narrow trepanning tool to reduce the load and feed with the cross slide to finish to size. The light was grear idea and a great design. Thanks for the video

[@sgresham21013]

wow. sir, I really appreciate the time you've put into the fantastic camera and audio quality. the high FPS and resolution, crisp and clear audio. first time watching your channel and now subscribed. in one video you've worked intimately with micro electronics, diagrams, machining work on mill and lathe and even metal working and bluing haha. awesome! and to boot some really fine craftsmanship. :)

[@thisolesignguy2733]

I just came across your video and channel, so I didn't really know what to think. But I was pleasantly surprised! I really enjoyed this. You gained another follower 😉

[@gklein4054]

Concise and Complete Thank You, Sir!

[@ollysworkshop]

Hi Matt, like you I've got lots of paused projects, and guess what.... one of them is a ring light for my mill! It's definitely one I need to get on with, as I'm always having to correct the lighting in mill shots in post. I really enjoy the way you put your videos together, very inspiring.

[@TheRecreationalMachinist]

Thanks Olly!

[@nielscremer599]

Instant subscription! Super cool work man, love it!

[@jesseskellington9427]

2:31 Nice graphics 😊🎉

[@hippotek1]

WOW! Nicely done!

[@johncollier7744]

Once learned a trick from an old engineer about bending small pipes without the risk of kinking. After annealing he would cut the pipe a few inches longer that was needed, crimp one end, fill with water, the crimp the other end so the water was trapped in the pipe. Since water won’t compress any bending of the pipe would be prevented from kinking because of the water. Once the pipe form was set, he would cut off the ends to release the water.

[@donaldvantongeren8385]

Real nice job! You inspired me and I’ll add ones to my drill press and mill 😊

[@lewisheard1882]

Wow! What a delightful video! A real gem and an instant subscribe.

[@olleolsson7837]

I freaking love your video style. The voice is just wonderful. The pace is calm and the editing is lovely. Just waiting for more greatness to come. Thank you for making great videos and inspiring me and others. I wish you all the best. //Olle

[@TheRecreationalMachinist]

Thanks for your encouraging words! 👍 🇬🇧

[@dainius4168]

Top tier content right here

[@robinwheatley4476]

Nice job.

[@slowstick86]

Just found your channel and subscribed. Great idea and very well explained. Video is very well done