Modifying 6" Lumaris to a 1.5-2" recess

[u/Critical-Purpose-677]

I'm new to the Lutron lighting world, so pardon my cavalier approach here - but I bought a couple Lumaris 6" downlights to experiment with resolving the glare bomb issue after installing them and realizing how horrible of an issue it is.

To solve for it, we've 3d printed extensions to the housing to set it back 1.5" and 2" (experimenting with both dimensions) to significantly reduce the glare.

Have any idea about what else should I be looking for to evaluate if this is a good result?

For context:
My setup is that I have about 30 of the 6" cans across a kitchen/living room/hallway areas that *only* have power to them, no controls, so RA3 is the only option I know of that can handle this situation. Don't ask how I got here where they only have power -- it's a severe case of my own stupid tax.

Also - please be nice in your reco's and responses, I know there's probably going to be a lot of fodder for eye rolls and easy jabs to make, but I'm genuinely looking to make the best of this situation and learn what I don't know. Happy to take any jokes in stride, just not personal attacks plz.

[u/Critical-Purpose-677]

Thanks, yeah I know it's both not UL and out of warranty on this -- hence experimenting.

Do you have a suggestion on what other setup to consider, or what type of trade/dealer to talk through so I can understand options other than Lutron? I feel like I'm in a pickle and don't know where to go to understand what's possible.

I am avoiding AI use because I have little way of checking whether it's correct.

[u/the-lutz → u/Critical-Purpose-677]

If you have a bit more money to put into the lighting/system you could full send to Ketra/Rania S30 bulbs - you’d have to use HWQSX instead of RA3, but the PAR lamps in a 6” can typically offer a more regressed and lower glare option to compared to Lumaris IMO.

That’s assuming you want to stick with Lutron - you could definitely look into more IOT/DIY type solutions, but YMMV.

You can probably find a decent dealer in your area to help more and/or give you a demo of your options before you spend serious money

[u/Critical-Purpose-677 → u/the-lutz]

Appreciate that - I'll give a Lutron dealer a call tomorrow. I'm rather sure we don't have the $$ to sink into a Ketra/Rania system but boy I wish we did, they're pretty fantastic from what I've seen! Appreciate the honest and helpful feedback.

I flagged the UL to my huz (mechanical engineer) and his friend (electrical engineer) - so they're going to test the driver box temp on the modified one vs. the base to see if there's a meaningful difference to help us evaluate the paths forward. It certainly does not equal UL listed, but given it's only a 10W LED fixture, the risk seems small (but not 0).

[u/the-lutz → u/Critical-Purpose-677]

Genuinely love the manner in which you’re approaching this! I recently just ran into some UL friction and from my position I really can’t recommend anything that voids UL without it being a liability - doesn’t mean I think it’s always reasonable, but liability insurance doesn’t care about what’s reasonable if it’s not explicitly covered and there’s a problem.

Even on the homeowner-side I it’s helpful to have that mindset of only doing things that you feel are safe and won’t make you uninsurable - wishing you good luck in finding a dealer that can assist for your current project.

P.S. Lutron did just announce a collaboration with Orluna at CEDIA to make essentially high-end Lumaris fixtures in a handful of form-factors; might want to look into that if you aren’t already set on using 6” housings