DIY Emergency Gadget: 50W LED Torch With Dual USB Power Bank

Step 1: Open the LED Bulb Case

• First, take your old LED bulb.
• To make opening easier, slightly heat the sides (you can use a hair dryer or heat gun on low).
• Gently press and twist the diffuser (white cover), and it will pop open.
• Once open, carefully remove the LED plate with its heat sink and the old driver circuit inside.
• Now you’ll have an empty LED bulb shell, ready to be reused for your DIY torch + power bank project.

Step 2: Fix the High Power LED

• Take a 12V 25W or 50W High Power LED / COB LED.
• Apply a thin layer of thermal paste on the backside of the LED for proper heat transfer.
• Place the LED on the old bulb’s aluminum heat sink plate (backside of the LED board).
• Drill two small holes on the plate, align the COB LED, and use screws to fix it tightly in place.
• Now solder red wire to + (positive) and black wire to – (negative) terminals of the LED.
• Make the wires come out to the backside of the heat sink for further connections.

Step 3: Mount the XL6009 Module

• On the backside of the COB LED’s heat sink, fix a spacer/stand-off to create some gap.
• Place the XL6009 boost converter module on the spacer and screw it tightly.
• This ensures the module stays firmly attached while leaving enough space for air circulation and safe wiring.
• Keep the input/output pins of XL6009 easily accessible for connecting the LED and battery later.

Step 4: Modify the Power Bank Module

• Take your power bank fast-charging module (with dual USB ports).
• On the board, you’ll see a small digital display soldered with a 5-pin connector.
• Carefully desolder the display from the board.
• Solder 5 wires (around 3 cm long) to the board’s display pins.

Step 5: Make Acrylic Case for Power Bank Module

• Take a piece of acrylic sheet (you can get it laser-cut at a local shop).
• Design a small box enclosure as per the size of the power bank module.
• Ask for cut-outs/holes in the acrylic for:
• The USB ports
• The digital display
• The ON/OFF switch
• Fix the power bank module and its extended display into the acrylic case using screws or glue.
• Glue the acrylic pieces together to form a sturdy box.
• For the switch connection:
• Solder one wire from the +ve output of the power bank module to the switch.
• Take another wire from the switch output to your circuit.
• Connect a negative wire directly from the power bank module –ve terminal.

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Step 7: Mount the Acrylic Box on the Bulb Case

• Take the old LED bulb case and mark a square cutout the same size as your acrylic power bank box.
• Carefully cut out the square section using a rotary tool or sharp cutter.
• Use a small file to clean and smooth the edges for a proper fit.
• Insert the acrylic power bank box into the hole.
• Apply strong glue around the edges to fix it firmly in place.
• Make sure the USB ports, display, and switch are properly aligned and visible from outside the bulb case.

Step 8: Wiring XL6009, PWM Controller, and LED

• Connect Power Bank to XL6009:
• From the power bank module (switch wires), solder one wire to the +IN of XL6009 and the other to the –IN of XL6009.
• Add PWM Controller:
• Connect XL6009 OUT + to PWM controller +IN.
• Connect XL6009 OUT – to PWM controller –IN.
• Connect PWM to LED:
• From the PWM controller, connect OUT + to the LED + (red wire).
• Connect OUT – to the LED – (black wire).
• Fixing the Potentiometer:
• Use a screwdriver to tighten the PWM controller.
• Place the PWM potentiometer knob on the backside of the LED case.
• Remove the old bulb’s male cap, and fit the PWM pot shaft there.
• Glue the pot in place and fix the knob for easy brightness control.

Step 9: Battery Holder and Final Connections

• Take a 3-cell 18650 holder (parallel type) and place 3 × 18650 batteries inside.
• Solder the –ve side (black wire) of the holder.
• Solder the +ve side (red wire) of the holder.
• Now connect the holder –ve wire to the power bank module –ve terminal.
• Connect the holder +ve wire to the power bank module +ve terminal.
• Double-check all connections to ensure correct polarity before powering ON.

Step 10: Final Assembly

• After completing all wiring, turn ON the power bank switch.
• Use a screwdriver to adjust the XL6009 output to 12V (check with multimeter).
• Once the correct voltage is set, fix all modules (XL6009, PWM controller, battery holder, wiring) securely inside the LED bulb case with glue or screws.
• Place the diffuser/LED cap back on the bulb case and close it properly.
• Your Power Bank + High Power Torch is now fully ready.
• Test the USB outputs for charging and turn ON the LED torch — adjust brightness with the knob.

Step 11:

• You can charge the built-in batteries using Type-C or Micro-USB input on the power bank module.
• You can also use the USB ports to charge your phone, headphones, or other gadgets.
• When you turn ON the switch, the torch LED lights up.
• Rotate the knob to increase or decrease brightness as needed.

Step 12: Watch It in Action

That’s it — your DIY Power Bank + High Power Torch from an old LED bulb case is complete!

You can charge devices, adjust brightness, and use it as an emergency light.

👉 Watch the video and enjoy! 🎥✨