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.