For some time now, I’ve thought about adding some basic lighting to my tool-shed. My garage has plenty of power (and even a solar array!) but the shed does NOT have regular 120V power running to it.
I’ve also worked on a few projects making use of Ryobi batteries, both the 18V and 40V versions.
It seemed to me that for as much and as often as I need lighting in my shed, a very simple battery-based system would work well.
I had already created some CAD files for a Ryobi 18V-based emergency backup power light, so I simply repurposed that and made a few modifications to use as a wall-mount battery holder. The main changes were to add tabs for screw holes, and a backer plate to help hold the electric contacts in place.
I printed this out of PLA plastic on my Ender 3 S1 3D printer. I simply set it to go at night, and it was ready the next morning. After removing the supports, I was ready to build the electrical components in the plastic shell.
At the heart of this design is the shape, which holds the battery in place. Where the end of the battery lines up, there are indentations on the 3D print to hold electrical contacts. I used Keystone 209 clips to make the electrical connection. https://amzn.to/46Lh2ci
I soldered a short piece of black wire to one of the clips and the end of an inline automotive fuse holder to the other. https://amzn.to/3M40hj1
The other end of the fuse holder goes to a DC rated switch. 20mm is a common size for switch mounting holes, so I designed the print to allow for popping one of those switches right in place. https://amzn.to/3YKhTYM
Another short wire comes off the output of the switch.
From there a pair of wire nuts connects the negative of the battery and the output of the switch to some lamp cord running to a light bulb holder. I love WAGO lever nuts. They are easy to use and allow for simple addition and removal of wires to a group. https://amzn.to/3YKhTYM
The fused wire goes on the positive side of the 3d print for the battery, and the plain black wire goes on the negative.
In the bulb holder, we are NOT just using any light bulb! To start with, we want an LED bulb, as they are so energy efficient. Another feature not talked about often enough is that they are durable! In a location like a shed, I am likely to accidentally hit a bulb with a shovel or other tool at some point. If you have ever had to clean up a shattered CFL bulb, you know what I’m talking about!
The other thing is that it will NOT be a typical 120VAC light bulb. Nope, we need one that can run on 18VDC. Fortunately, there are already LOTS of bulbs out there designed for 12V systems for automobiles, RVs, and camping trailers. Many of those bulbs will run fine on a Ryobi 18V battery, but the easiest thing to do is simply find a bulb with a WIDE DC INPUT RANGE. These LeMeng brand bulbs work great and will run on anywhere from 10-30VDC! https://amzn.to/4dFwPvp
I screwed the 3D print to the wall of my shed. Two of those screws went through the backer plate to help hold the 209 clips in place. The power switch faces towards the door for easy access. The bulb is mounted above the door, so it’s shining towards what I want to look at.
I inserted the battery into the wall holder and turned on the switch. POOF! LIGHT!
Nice and simple!
Could I have instead purchased a commercially-built Ryobi area light? Yes, I could, but new items get expensive fast, and I really wanted something designed for permanent installation in my shed. Also, the cost of DIY was minimal – just a few dollars in parts.
I also COULD have installed a purchased solar light, or perhaps even figure out how to solar-charge the Ryobi battery. Again, there’s additional cost and complexity. It also assumes the shed is located in a sunny area. Part of this project is to design something which can also be used at my friend’s off-grid property, deep in the woods. Solar really doesn’t work well where his shed is located.
Even a single Ryobi battery has enough power to easily run several lights. These bulbs take no more than 300mA of current. That means that one light will run for OVER 3 hours for every one amp-hour of capacity of a battery. For example, a popular 4AH battery will run a bulb more than 12 hrs.
In my case, I just want to be able to flick on the lights, find a tool or stored item I am looking for, and then turn the lights back off again. So, one charged battery might last 6 months!
I’m a big fan of low-tech and simple. A battery going straight to a bulb is about as simple as a flashlight. But it’s always there in my shed when I need it!
Until next time, stay charged-up!
-Ben Nelson
PS: If you want to make your own, the STL file is posted at: https://www.thingiverse.com/thing:6729458
