I'm much better with a soldering iron, razor saw, and glue than I am with sheet metal tools anyway (been a model airplane builder a couple times, and I've built some ham radio stuff from kits fairly recently). Suitable yellow LEDs are under a buck each, I've got a large surplus of little wall wart power supplies, and I know how to use a multimeter.
@MattKing Yes, safelight for multigrade is trivial -- I've got one already, a 15W red coated bulb in a reflector clamp lamp, used previously in my old darkroom, that I can direct at the (white, textured) ceiling and light at least half of my darkroom quite adequately. It's the RA-4 I'm trying to set up, and with no ability to even buy LPS other than replacement bulbs or actual Thomas safelights (which seem high just to get the electrics), not to mention the ten minute warm-up, I'm pivoting back to yellow LEDs (narrow emission between 475 and 500 nm, knowing they might still need filters).
Lots of cheap thomas safelights on ebay right now.
LED is dimmable with a fairly simple chopper circuit (a dual 555 chip
"Chopper circuit" is what I've heard for years to refer to anything that just "chops" up the DC into square wave pulses
custom PCBs are fairly cheap -- cheap enough it's not really worth sourcing the equipment and chemicals to make your own.
There are many ways to skin a cat, as they say.
A bit late to this thread, but I also had the Thomas safelight decades ago but it seems it was thrown out. I was interested in LPS light and wanted to recreate that several years ago. I found it wasn't too difficult to get a 35W Philips bulb, but the original ballast was much harder. On a tip, I tried a modern 35W solid-state fluorescent light ballast and that worked perfectly!
The socket does not actually support the bulb so I decided to just solder the ballast directly to the pins. I put the bulb inside a clear plastic 12" pencil box. I put aluminum foil behind it as a reflector which didn't really work because the shape has no accuracy.
I don't have any idea what to do about the Thomas filters, as I was just interested in the light - not the safelight.
I used this ballast from Amazon: Fulham Lighting WH2-120-C. The bulb was from eBay.
--Gary
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Here's what may seem like a wacky thought to add;
what about adding the appropriate Roscoe gel sheet/s to the inside of one of the porta-trace light tables? these should be fairly inexpensive used, decent low-profile housing and circuitry already handled. one may have to source some simple brackets and pop-rivets or other hardware, but I think many of us who tinker likely have that stuff sitting around already. The other addition I can think of would likely be an extension cord with a built-in switch unless one wants to re-wire the assembly also.
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