DOA = Dead on arrival....
I took the one i have done out with me last night and tested it and it is bright!!!
I used this epoxy, it is used to pour table tops with pics.
http://ecx.images-amazon.com/images/...NL._SY450_.jpg
I found that it is easier to make them with 2 pours. The first pour fill the cup up 1/2 way so that the PCB just sits on the resin.. (The kinda I used was pretty thin so the PCB wanted to float to the top when i tried to pour it all at once). then once it is hard enough, pour the second half to cap it off. I had a lot of bubbles at first, but they worked their way out before it dried.
I am going to mount the one i have complete as it will be 3 weeks before I get my other bulbs.