Tuesday, June 3, 2014

Light that side door!

Materials:
Bargman RV Porch Light without switch (Amazon.com)
JR 2 gang RV light switch (Amazon.com)
LED 1156 250 lumen bulb (Amazon.com)
Wire, connectors, grommet & caulking
Black spray paint for plastic

I wanted a black light fixture for this project, but all I could find was off white*, so the first step was to lightly scuff and wash the fixture body, then paint it black. The paint took several days to fully cure, but it looks good.

* I did find a black one, but it was a fancy one that came with a custom LED bulb and sold for $25. A $5 light, $10 bulb and paint I already had fit my budget much better.

Installation:

The old switch just inside the side door that controlled the dome light:



I had to widen the hole in the plywood, as the new switch needed more room behind it. After playing around with various small saws in an attempt to make certain that I didn't poke a hole in the aluminum skin that was only 1.5" past the plywood I finally remembered that I had bought a RotoZip several years ago for another project. This thing is made for cutting holes in sheet goods and once I'd spent 15 minutes figuring out where I had put it, the job was done in 5 minutes.  The power taps the power wire for the dome light with a simple jumper. As I'm going to be using all LED bulbs in the new setup, I'm not worried about the additional amp draw, as even with multiple lights running off the line, the total amperage will be 1/4 to 1/3 of the incandescent that was there.



And the finished switch, including some labels made with a Brother PTouch Labeler borrowed from work. There's a screw hole from the old one still exposed, but I'll drop a little wood putty into it to seal/hide it.



For the porch light itself, I drilled a 3/8" hole though the skin of the trailer, put a rubber grommet from Radio Shack in it and threaded the wires through to the switch and a ground point on the frame. I was originally going to screw it to the skin, but the thinness of the skin convinced me I'd be better off using aluminum blind rivets, so that's what I did. Pop the LED bulb in, replace the cover and apply a bead of caulking around the outside edge and we've got a porch light:



I like this light so much that I'm going to add a second one to the front of the trailer as a tongue/hookup light. I also found the Bargman model in black so I won't have to paint the second one.


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