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Making a Simple Green LED Fishing Light - Part 2 PVC Body

Updated on May 8, 2014

Let's Build the PVC Body!

Here is Part 2 of a four part series of articles that describe how to make a simple Green LED Fishing Light powered by a 9V battery.

  • Part 1 provides details for making the LED Circuit;
  • Part 2 details the construction of the PVC body;
  • Part 3 will cover assembly of the LED Circuit and the PVC body to make the light;
  • And then, Part 4 will provide for testing the light and it's use in the field.

Good Luck and Good Fishing!

Note: The video in the sidebar is the second version of the light; it uses one 9 volt battery and less powerful but also less expensive LED diodes.

Clockwise... 2 Connectors, 3" PVC Section. Threaded Cap. Plug, 2" diamater Lexan Polycarobonate
Clockwise... 2 Connectors, 3" PVC Section. Threaded Cap. Plug, 2" diamater Lexan Polycarobonate
File, Xacto Saw
File, Xacto Saw
PVC Primer and Cement, Silicone Caulk
PVC Primer and Cement, Silicone Caulk

Materials and Tools for the PVC Body

To make the PVC Body, obtain the material and tools listed in the section below.

Materials:

  • Two 2" Inside Diameter (ID) PVC Connectors
  • One 2" ID Threaded Female PVC Cap
  • One 2" PVC Plug
  • One 2" ID PVC Section cut to 3" in length
  • One 2" Diameter Lexan Polycarbonate Plexiglas (.093" Thick)
  • PVC Primer and Cement
  • Silicone Caulk


Tools

  • Hacksaw (or power tool to cut PVC)
  • Xacto Saw (or Hacksaw)
  • File


Testing Material:

  • Decoy Weights (or similar weight)
  • Tissue Paper
  • Bucket of Water
  • Plumber's Tape

Click thumbnail to view full-size
2" Diameter Lexan Plexiglas2.5" PVC Section
2" Diameter Lexan Plexiglas
2" Diameter Lexan Plexiglas
2.5" PVC Section
2.5" PVC Section

Step 1 - Plexiglas and PVC Preparations

In Step 1, the Lexan Plexiglas is cut square, trimmed and filed to a 2" diameter circle, and then the PVC Section is cut to a 3" length. To begin this step:

  • Cut the Plexiglas in a 2.5" x 2.5" square.
  • Center the PVC Section on to the square
  • Trace the inside diameter of the PVC section on to the square
  • Cut and file the square piece of Plexiglas to create a 2" diameter lens (see sidebar for cutting details)
  • Finally, cut the PVC to a 3" length and then de-burr the rough edges.

Note: Lexan Plexiglas comes in 8"x10", 12"x12", and larger sheets. PVC comes in 2', 4', and 8' sections. If able, scrounge around for scrap pieces of material or purchase second hand. Else, if making only one light, go with the 8"x10" Lexan Plexiglas and the 2' section of PVC.

Click thumbnail to view full-size
Dry Fit parts using sequence in the picture: Connector, Lexan Plexiglass, 3" PVC Section, Connector, Threaded Cap, Threaded PlugParts are dry fitted; all looks well!
Dry Fit parts using sequence in the picture: Connector, Lexan Plexiglass, 3" PVC Section, Connector, Threaded Cap, Threaded Plug
Dry Fit parts using sequence in the picture: Connector, Lexan Plexiglass, 3" PVC Section, Connector, Threaded Cap, Threaded Plug
Parts are dry fitted; all looks well!
Parts are dry fitted; all looks well!

Step 2 - Dry Fit the Parts

In Step 2, the parts are dry fitted together to ensure part fit correctly. To begin,

  • Dry fit the parts as described in the picture in the sidebar - specifically, PVC Connector, Lexan Plexiglas, 3" PVC Section, PVC Connector, Threaded Cap, Threaded Plug.
  • If all parts fit tightly, proceed to Step 3. If they do not, use the file on the appropriate part to carefully remove material.
  • In most cases, the PVC parts will fit snugly but the 3" PVC Section may require filing to remove burrs when it was cut to length.
  • For the 2" Diameter circular piece of Lexan Plexiglas, it may also require filing in order to dry fit it to the PVC Connector.
  • Once all parts have been dry fitted successfully, proceed to Step 3.

Click thumbnail to view full-size
Silicone Sealant, PVC Connector, and 2" Diameter circular piece of Lexan PlexiglassLens installed in the PVC Connector and Silicone Sealant applied.
Silicone Sealant, PVC Connector, and 2" Diameter circular piece of Lexan Plexiglass
Silicone Sealant, PVC Connector, and 2" Diameter circular piece of Lexan Plexiglass
Lens installed in the PVC Connector and Silicone Sealant applied.
Lens installed in the PVC Connector and Silicone Sealant applied.

Step 3 - Assemble the Lens Cover

In Step 3, the Lens (2" diameter Lexan Plexiglas) is sealed inside the PVC Connector to make the Lens Cover.

  • Do a final dry fit of the Lexan Plexiglas and the PVC Connector. It should fit tightly with no gaps showing between the Lexan Plexiglas and the inside lip of the PVC Connector. If there is a gap, you will need to cut and file another Lens. Else, proceed to the next bullet item.
  • Apply Silicone Sealant to the inside lip of the PVC Connector, and then install the Lens. Push firmly to ensure no bubbles have formed and a good seal has formed between the Lens and the inside lip of the PVC Connector.
  • Next, apply Silicone Sealant to the other side of the Lens (outside part that will be exposed to water).
  • While the sealant is still wet, use a wet cloth wipe any residue that may have gotten on the Lens.
  • Finally, let the sealant dry per the instructions on the container, and then proceed to Step 4 (in our case, we waited overnight for the sealant to cure).

Click thumbnail to view full-size
PVC Connector and Threaded CapParts fitted and cement applied.
PVC Connector and Threaded Cap
PVC Connector and Threaded Cap
Parts fitted and cement applied.
Parts fitted and cement applied.

Step 4 - Assemble the Lower Body

In Step 4, the Lower Body is assembled using the other PVC Connector and the PVC Threaded Cap.

  • Follow the directions on the PVC Cement container to prepare and cement the PVC Connector to the PVC Threaded Cap.
  • The PVC Cement used in this article called for applying primer to the inside of the PVC Connector and to the outside of the PVC Threaded Cap (non-threaded end).
  • Then, almost immediately, this was followed up with applying the cement to the primed areas.
  • This was followed quickly with a firm push to both pieces to seat the parts in place, and then a 1/4 turn to seal them.
  • Once the parts are in place, proceed to Step 5.

Click thumbnail to view full-size
Lens Cap, 3" PVC SectionCompleted Upper Body
Lens Cap, 3" PVC Section
Lens Cap, 3" PVC Section
Completed Upper Body
Completed Upper Body

Step 5 - Assemble the Upper Body

In Step 5, the Upper Body is assembled using the other Lens Cap and the 3" PVC Section.

  • Same as Step 4 with respect to cementing, just different parts to cement.
  • Once parts are in place, proceed to Step 6.

Click thumbnail to view full-size

Step 6 - Final Assembly

In Step 6, the Upper Body and Lower Body are assembled to make the PVC Body

  • Same as Steps 4 and 5 with respect to cementing, just different parts to cement again.
  • Once parts are in place, let the PVC Cement dry per the directions on the container before proceeding to Step 7 (in our case, we waited 24 hours for the cement to dry before proceeding).

Click thumbnail to view full-size
Decoy Weight, Tissue Paper, Assembled PVC BodyCover decoys weights in tissue paper and place in to PVC BodyInstall the Threaded PlugInstalled plug is secure, ready to testPlace weighted PVC Body into a bucket of waterPVC Body is completely submerged; water test begins
Decoy Weight, Tissue Paper, Assembled PVC Body
Decoy Weight, Tissue Paper, Assembled PVC Body
Cover decoys weights in tissue paper and place in to PVC Body
Cover decoys weights in tissue paper and place in to PVC Body
Install the Threaded Plug
Install the Threaded Plug
Installed plug is secure, ready to test
Installed plug is secure, ready to test
Place weighted PVC Body into a bucket of water
Place weighted PVC Body into a bucket of water
PVC Body is completely submerged; water test begins
PVC Body is completely submerged; water test begins

Step 7 - Test It

As a precaution against damaging the LED Circuit, Step 7 is a water test to ensure the PVC Body is waterproof.

  • Take two decoy weights or other weighted object that will fit inside the PVC Body and wrap them with tissue paper, and then place them into the PVC Body.
  • Next, apply Plumber's Tape to the PVC Threaded Plug's threads, then screw the plug securely in place.
  • Then, fill the bucket with water and sink the PVC Body into the water. Be sure the PVC Body is fully submerged and remains underwater for at least an hour.
  • Then, take out the PVC Body and check for water.
  • If the tissue paper is wet, then fill the PVC Body with water, screw the Threaded Plug in place, and search for the leak. Once found, use Silicone Sealant to plug the leak, and then re-test.
  • If the tissue paper is dry, then the PVC Body is waterproof. You are done.... standby for the next article!

Finished PVC Body

Click thumbnail to view full-size

Part 3 is Posted!

Part 3 of the four part series of articles that describe how to make a simple Green LED Fishing Light powered by a 9V battery is posted!

Part 3 covers the assembly of the LED Circuit and the PVC body to make the light! Check it out at "Making a Simple Green LED Fishing Light - Part 3 Final Assembly".

Till then,

Good Luck and Good Fishing!

PS: If you are in a hurry, do check out the workarounds below that use a Mason Jar in the first example and a sealed glass container in the second example. They both work!

Easy Workaround with a Mason Jar

Click thumbnail to view full-size
Use a Mason JarSecure the LED Circuit and Battery to the Cap.Works like a Charm!Top View
Use a Mason Jar
Use a Mason Jar
Secure the LED Circuit and Battery to the Cap.
Secure the LED Circuit and Battery to the Cap.
Works like a Charm!
Works like a Charm!
Top View
Top View

Easy Workaround with a Sealed Glass Container

Click thumbnail to view full-size
LED Circuit Assembly and Sealed Glass ContainerSealed Glass Container... $1.99 at the Container StoreLED Circuit Assembly (wrapped with black electrical tape)LED Circuit Assembly installed upside down and battery connectedWater testing with the light on!  No need to add weight, sinks with battery and LED Circuit Assembly installed.Sealed Glass Container workaround works!
LED Circuit Assembly and Sealed Glass Container
LED Circuit Assembly and Sealed Glass Container
Sealed Glass Container... $1.99 at the Container Store
Sealed Glass Container... $1.99 at the Container Store
LED Circuit Assembly (wrapped with black electrical tape)
LED Circuit Assembly (wrapped with black electrical tape)
LED Circuit Assembly installed upside down and battery connected
LED Circuit Assembly installed upside down and battery connected
Water testing with the light on!  No need to add weight, sinks with battery and LED Circuit Assembly installed.
Water testing with the light on! No need to add weight, sinks with battery and LED Circuit Assembly installed.
Sealed Glass Container workaround works!
Sealed Glass Container workaround works!

Comments

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    • Ann1Az2 profile image

      Ann1Az2 

      4 years ago from Orange, Texas

      Cool idea and excellent instructions! Even I can follow them! lol

    • hbng84 profile imageAUTHOR

      hbng84 

      4 years ago

      Was out with the significant other today and happened by a sealed glass container on sale for $1.99. Perfect workaround to the PVC Body!

    • hbng84 profile imageAUTHOR

      hbng84 

      4 years ago

      Part 2 of a four part series of articles is done! Do check it out; also do check out the workaround that uses a Mason Jar as a waterproof container!

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