
Safety and thermal check: Custom enclosure for de-bulbed 230V DOB LEDs + Axial fan static pressure question
Hi everyone,
I’m building a custom DIY botanical enclosure out of a plastic barrel (about 80L / 21 Gallons, 80cm tall) and I need a serious safety and engineering reality check on my current setup. I'm doing this as a hobby to learn some basic hardware skills, but I want to make it 100% safe.
I have two main questions:
1. De-bulbed 230V DOB LED Insulation
The Setup: I am running 5x 13W DOB (Driver on Board) E27 AC LED bulbs (total 65W, 230V mains). I removed the plastic diffusion globes to maximize light efficiency.
The Hazard: The PCB tracks, components, and solder joints are now completely exposed and live at 230V.
Current State: I put some electrical tape on one plate just for a quick test, but I was warned that these aluminum plates can easily reach 185°F to 203°F (85°C - 95°C) under continuous load. The tape adhesive will obviously degrade and fail, creating a major short/fire hazard.
Available Materials: I have some flat PP5 (Polypropylene) storage lids, about 1-2mm thick.
The Question: Can I safely cut these PP5 lids to form small, individual protective caps/shields over each naked LED plate (with drilled air holes)? Or will the continuous radiant heat cause 1-2mm PP5 to suffer from thermal creep/warping over time, risking direct contact with the live 230V components?
2. Axial Fan vs. Carbon Filter Static Pressure
The Exhaust: I have a 120mm (4.7") In-line Axial fan rated at 17W, with a declared airflow of 90 CFM (152 m³/h).
The Resistance: It needs to push/pull air through a 4" (100mm) carbon filter with a 1.5" (38mm) thick carbon bed.
The Question: Knowing that axial fans have notoriously low static pressure, will a 17W fan be completely choked by a 1.5" carbon bed? I'm worried it will kill my airflow entirely, leading to a thermal runaway inside the enclosure.
I'm attaching photos of the exposed PCB plates, the tape test, the overall enclosure layout, and the fan specs.
Any data-backed advice on how to properly insulate those live plates and manage the pressure drop would be massively appreciated. Thanks!