Ok. FINALLY got The rest of the project done with my LED pro hood retro. So here goes the long description.
So first was all the parts. I got the following parts to start the project. 1 Maxwellen 48Watt Dimmable LED driver (7-12 3watt LEDs), 12 - Bridgelux 3 watt LEDs on stars (6 - Royal Blue 4 - True blue 2 - UV LEDs), Arctic white heatsync paste, roll of 16 gauge wire, Solder and soldering station, PC power cord, drill and drill bits, Heat shrink tubing and heat shrink gun, time.
So those of you who have the LED Pro hood know that it is very bright and very white. This configuration grows corals quite quickly but doesn't do much for color.
So first I removed the hood and removed the splash guard from over the reflector and LEDs. I removed the reflector and decided on the LED placement. I decided that I wanted to leave the stock LEDs in place and work around them. So I chose spots around the perimeter. I took the reflector and used a sharpie marker to mark a dot where I thought each LED should go. I then found a drill bit the same size as the stock holes and drilled through the reflector. I hindsite what I should have done was place the LEDs and then mark their location on a piece of paper (the old charcoal rubbing Idea) so that I could drill them to match. The reason this should work better is because I ended up having to file a few of the stars down to get them to line up with the holes I had drilled because they were too close to the stock LEDs.
So here is the first picture showing my chosen layout with the LEDs already placed and the wires soldered.
All the LEDs on white plates are the stock ones. All the ones on small black stars are the new ones. The yellow wire should lead you on the path.
Here is a close up of one of the stars I had to file to get it aligned.
The stars simply "glued" in place with the arctic white heatsync paste and left to set over night. Then they are all soldered in series. I mounted the driver using Velcro into the channel where the stock dawn/dusk driver is mounted. The red and black wires go under the reflector and connect to the LEDs. The two white wires on the top go to the POT that is used for dimming and the two white wires on the bottom connect to the power cord.
Here is the picture showing the inside after drilling mounting and soldering everything inside the hood. The POT is mounted through the top of the hood where all of the wires come in at the bottom left of the picture. It hard to see in there but it's there.
After running the hood with the new LEDs for a couple of days it was clear that the stock fans were not keeping up with the extra heat coming from the new LEDs. So I started working on another fan to help move more air. I took a 120mm PC cooling fan and just laid it on top of the hood over the vent slots for a couple of weeks to see if that was enough. The tank still changed temp about 2.5 degrees from morning to evening but I was fine with that. So I started to make plans to mount the fan.
I removed the hood and pulled the entire heatsync out of the hood to decide where best to put the fan. As I was doing that I decided to test fit the heatsync into the hood with the fan to see how much clearance there was. There was none. In fact the heatsync was no where close to touching the posts that it mounts too. So plan B.
I looked online for a 120mm fan that was thinner to fit in the space. The problem with all the ones I found was that they were so thin that there were no ball bearing version (needed for good long life) and the CFM rating on them was less than half of the fan which I had tested. Plus the reviews on all of them said they were either noisy or didn't last. I decided to trim the tabs off of half of the fan I had been using and then allow it to stick out of the top of the hood a small amount as a compromise.
So first thing is modify the fan. Here's the pics.
Original Ball bearing 120mm fan
I used a dremel with a cut off wheel to cut the ears off the one side to get this.
and a side view.
Then I marked the top of the hood where the fan hole would be cut.
I used my trusty dremel with a cutoff wheel again to cut the hole.
More to come