modify a cree cf6 to fit in a square recessed downlight housing

Modifying a Cree CR6 to fit in a square recessed downlight housing : 

Modifying a Cree CR6 to fit in a square recessed downlight housing Cree designed their CR6 for cylindrical ceiling fixtures. Their 3 pop-out clips will not secure the fixture into a square housing

If the housing uses spring clips, minor modifications to the CR6 body allow it to fit snugly and safely into a square fixture: 

If the housing uses spring clips, minor modifications to the CR6 body allow it to fit snugly and safely into a square fixture

Remove the bulb and trim from the existing housing as described in the Ecosmart CR6 instructions: 

Remove the bulb and trim from the existing housing as described in the Ecosmart CR6 instructions Cree CR6 O ld Trim with spring clips

Drill out the rivet securing the spring clip on the old housing: 

Drill out the rivet securing the spring clip on the old housing If the rivet spins with the drill bit, wedge a screwdriver under the retainer clamp to hold it in place while drilling

Carefully determine the distance from trim exposed surface to the clip mounting hole: 

Carefully determine the distance from trim exposed surface to the clip mounting hole In this case the mounting hole was ¾ inch from trim bottom

Mark where holes should be drilled in the CR6 body One clip must be mounted on each side of the body: 

Mark where holes should be drilled in the CR6 body One clip must be mounted on each side of the body

Drill holes large enough to accommodate the screws that will be used : 

Drill holes large enough to accommodate the screws that will be used In this case 6-32 x 3/8 screws were used

Paint the screw heads to match the CR6 fixture color: 

Paint the screw heads to match the CR6 fixture color Appliance white or any semi-gloss white will work

Attach the retaining bracket and spring clips to the CR6: 

Attach the retaining bracket and spring clips to the CR6 Be sure to orient the bracket and clip the same way they were on the original trim. A lock washer is recommended. Tighten securely

Properly installed, the retaining screw should be barely visible: 

Properly installed, the retaining screw should be barely visible

The CR6 after spring clips have been mounted: 

The CR6 after spring clips have been mounted

Install the CR6 into housing using the newly attached spring clips: 

Install the CR6 into housing using the newly attached spring clips

Press fixture into place Note that screw heads are barely noticeable: 

Press fixture into place Note that screw heads are barely noticeable

voila: 

voila

Payback Analysis Assume electricity cost of 11c/kwh & 6h/d usage: 

Payback Analysis Assume electricity cost of 11c/kwh & 6h/d usage Device Power/day Cost/d Cost/ y Cost/ 2 y Cost/ 3 y Cost/ 10y Incand 65w .390 kwh $0.0429 $15.65 $31.30 $46.95 $156.50 CR6 10.5w .063 kwh $0.00693 $2.53 $5.06 $7.59 $25.30 Assuming you can buy a Cree CR6 for ~ $40 and use it an average of 6 hours per day instead of an incandescent bulb, you will recover the cost of the CR6 in about 3 years. The CR6 advertises a 25 year life expectancy. An incandescent bulb would cost $313 (excluding the cost of replacement bulbs every year or two), whereas a CR6 would cost $63.24 to operate during that time – a savings of ~ $250 in electricity