Finally got around to working on the LED's. With the kid on the way, other priorities have slowed me down. 
Took me a while just to cut the aluminum, create the sections, clean everything and use adhesive to glue the LED's to the aluminum. I had considered drilling individual holes for each, however the thought of 216 holes didn't appeal to me. I know that I can chisel any LED's that need replacing off if needed. I also learned that a very small tube of adhesive goes a LONG way. If anyone need adhesive, let me know. I have 3 unopened tubes of Arctic Aluminum left over and at least 1/2 of another tube.
Soldering believe it or not wasn't really all that big of a deal. Last time I soldered something was probably 25 years ago. Everything went smooth when pre-tinning the + & - tabs on the LED's.
I still have to cut wire to length and pre-tin the wire. After that I have all the stuff needed for finishing, just need to DO IT. lol Actually, I still need a thin piece of acrylic to use as a splash shield. I will also be using 60 degree optics on the cool whites, and no optics for the royal blues.
Here are a couple pics of the sections going above the three openings. They are four rows of nine LED's each. Total of 108 with 72 royal blue and 36 cool whites. The three sections will be connected to each other with the left over aluminum so it'll be one solid unit hanging from the ceiling. They are 12" wide by 19" long so they should cover the opening nicely.
Took me a while just to cut the aluminum, create the sections, clean everything and use adhesive to glue the LED's to the aluminum. I had considered drilling individual holes for each, however the thought of 216 holes didn't appeal to me. I know that I can chisel any LED's that need replacing off if needed. I also learned that a very small tube of adhesive goes a LONG way. If anyone need adhesive, let me know. I have 3 unopened tubes of Arctic Aluminum left over and at least 1/2 of another tube.
Soldering believe it or not wasn't really all that big of a deal. Last time I soldered something was probably 25 years ago. Everything went smooth when pre-tinning the + & - tabs on the LED's.
I still have to cut wire to length and pre-tin the wire. After that I have all the stuff needed for finishing, just need to DO IT. lol Actually, I still need a thin piece of acrylic to use as a splash shield. I will also be using 60 degree optics on the cool whites, and no optics for the royal blues.
Here are a couple pics of the sections going above the three openings. They are four rows of nine LED's each. Total of 108 with 72 royal blue and 36 cool whites. The three sections will be connected to each other with the left over aluminum so it'll be one solid unit hanging from the ceiling. They are 12" wide by 19" long so they should cover the opening nicely.

