DIY LED thermal epoxy replacement

BradB

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I've ran DIY LEDs for around 15 years. LEDs are directly attached to two 24"x48" aluminum sheets that are both the lid of my canopy and function as heat syncs. This almost worked without any additional cooling, but I did add a fan for longevity. Every few years, I remove any dead/dying LEDs and add new ones. I attach LEDs using arctic silver alumina premium ceramic, which was less than $5 when I started. Now it is $25. If I do both panels separately once a year, that was < $10/year and now is $50/year.

I don't know if DIY LEDs still make sense in 2026, but if I continue to use them, I need a cheaper physical attachment and thermal solution. What is everyone using?

I had a scare this morning - half my LEDs didn't turn on, and I suspected my HLG-480H-54 ($180) but it turned out to just be a 20-year old timer that finally failed. But this got me thinking about either going to premade fixtures or getting around to replacing dead/dying LEDs.
 

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