Whelen Halogen Responder replacement bulb reflector

JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
Which generation, there are 5 main types. The 4 older ones are shown below then there is one additional newer type that is similar to the 4500 ambulance bar rotator. I should have some of each. If you mean the single beacon, the rotators were the same a G1 and G2 mini lightbars.


respgen.png
resap5.png
 
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coop359

Member
Apr 16, 2012
495
USA Tennessee
Hi. It is the first type. Flatter rectangular reflector with a nut on the bottom inside the reflector. Are those bulbs replaceable or do you have to replace the whole unit? Thanks
 

JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
The version with the replaceable bulbs often had damaged contacts and you ended up replacing the reflector anyway. Alos, usually the reflectors were so heat damaged you might as well replace the whole thing. These were also used as Advantedge alley lights. I think I still have a whole reflector or two sitting somewhere, I just replaced a bunch of them in my collection. I had a bad ground on a few of them instead of bad bulbs so I don't think I used up the reflectors. I will look.

Non-relampable
PXL_20230509_030716382.jpg
PXL_20230509_030435816.jpgPXL_20230509_030354342.jpg

Relampable
PXL_20230509_030633326.jpg
Someone used a marker light bulb here instead of the correct bulb. The base is similar.
PXL_20230509_030530574.jpg

Marker light with similar base
s-l500.jpg

Correct bulb "ERF" 50 watt https://www.replacementlightbulbs.com/lamperf.html
erf.jpg

I only have one NOS reflector bulb combo, and a few used 5 out of 10 ones. I don't want to sell my last replacement, I thought I had more. I would be happy to sell you a used woking one for $20. I have some advantedge bars that don't use their alley lights that I bet have decent ones in them, i can get some pictures for you tomorrow.....
 
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JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
Here is what I have, a few that look like the one on the left, 5 out of 10 but working, and a few from advantedge alleys that look like the one on the right, 7 out of 10 at least. I also have a like new reflector with a bad bulb with which I am going to make an ill-advised mod and drill out the socket and add a different bulb, we shall see how that goes.

I'd take $20 for the one on the right, and throw in the one on the left for free if you pay shipping.

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JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
So..... I have figured out that you can make the "non-replaceable" ones relampable. I removed the pinned bulb from a H27SN and H50SN bu heating up the pins and melting the solder. I then had a pinned bulb and a shell of the snap in part. I drilled out the reflector and liquid plastic-ed the SN bse into the hole. Then I was able to slip the pinned bulb, or any pinned bulb i liked through the holes and bend the pins.

I made a short video of the process. Probably no worth the time, but I felt the reflector had challenged me.

I will upload the video when it is done.

PXL_20230509_163821863.jpgPXL_20230509_163931952.jpgPXL_20230509_164101321.MP.jpgPXL_20230509_163933716.jpgPXL_20230509_163825898.MP.jpgPXL_20230509_163928083.jpgPXL_20230509_164047568.jpg
 
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JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
I made some revisions so that the bulb sits in the right focal point of the reflector. I also destroyed another already bad reflector along the way.rev1.jpgrev2.jpgPXL_20230509_191951990.jpg
PXL_20230509_192318354.jpgPXL_20230509_192325120.jpgPXL_20230509_193221852.jpgrev11.jpg
revised3.jpgrevised2.jpg
rev9.jpgPXL_20230509_193211536.jpgrevised1.jpg


Once the plastic dries I will test the light pattern and distribution.
 
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JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
Nice. I was thinking the same thing. Have not had time to pill it apart yet. Thanks
I can provide a few tips:

- Extract / break the old bulb first, then make your mounting hole. It's going to break either way, you might as well have control over when and in what direction.

- Wear eye protection. Seriously, don't just squint. No really, I wore eye protection and I typically use the "squint and look away" method.

- Take your time and expect a dusty mess. The dust made by the plastic housing and ceramic bulb socket taste like cancer and make sharp snot later. Wear breathing protection.

- I used a dremel and a drill. A cut-off disc and sanding drum for dremel and smaller bit then unibit on the drill.

- The back rectangle piece will disintegrate / fracture and is in the way for using other bulbs. Dremel it off unless you can cleanly drill it with gradually increasing bit sizes. If the breaks it takes the reflector with it.

- Liquid "high temp" electrical plastic / tape /sealer seems to hold the bulbs fine. I ran one 3 hours with no melting or problems. There are a few brands of liquid electrical tape and plastic. Both types (rigid and softer) worked. I used this instead of the epoxy that I thought of first. Temp rating matters.

- 27w bulbs are plenty. I suggest a H27SN bulb, vertical filament. Leave it in the base, cut the tabs off, make a hole the size of the base, and give yourself room to come forwards and backwards with placement. If you make a better sized hole you will use much less liquid plastic.

- Pay attention to the focal point of the reflector. My first attempt the bulb protruded too much. The original bulbs sit back in a bit. Thi is why I think anything over 27w will be trouble heat-wise.

- Take your time and expect a dust/glass/misc mess.
 
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JohnMarcson

Administrator
May 7, 2010
10,971
Northwest Ohio
Final versions, plastic all set.
PXL_20230510_234224722.jpgPXL_20230510_234228707.jpg

I tried to keep distances the same, but I moved a bit. It's close. There wasn't much variation between the replacements or the factory.

PXL_20230510_233020478.MP.jpgPXL_20230510_233022393.jpgPXL_20230510_233100019.jpgPXL_20230510_233102318.jpgPXL_20230510_233130766.jpgPXL_20230510_233134311.jpgPXL_20230510_233135767.jpg
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No difference in external or internal heat after 30 min. They look pretty much the same to me.
 
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