Celica GT4 Fog Light Reflector (fits AT160)

Summary

This weekend I decided to repair my 1989 Celica's fog lights. In this video I use my 3D printer and my CAD knowledge to reverse engineer the original fog light reflector.

You can also go give me a follow on Linked in.If you liked this model you might also like my Youtube Channel From Rags to Wrenches where I upload videos about my learning experiences as a vehicle mechanic. I plan to upload videos about 3D prints and electronics in the future as well.

You can also go give me a follow on Linked in.

Print Settings

Printer brand: Creality

Printer: Ender 3 Pro

Nozzle: 0.4
Layer Height: 0.2
Walls: 5
Infill: Gyroid
Infill percentage: 40%
Cooling: 20% or off
Hotend Temp: 250ºC
Bed Temp: 95ºC
Support: Tree
Bed adhesion: 8mm Brim

Rafts: No

Filament brand: eSun

Filament material: ABS+

Notes:

Important!!!

1. Use an enclosure to minimize the chance of a failed print.
2. Minimize the cooling or turn it off (the support side will not look nice but you are going to get a strong part in return).
3. Place the part facing up (the side with the groove should face up and the small hole in the middle should face the build-plate).

Post-Printing

Repair: Making the fog light reflector

You need to process the original fog light in order to use this print. Here's a link to my Youtube Video on how to make this: 3D Print Car Parts? Repairing the Fog Lights for the Toyota Celica GT4 🚗🏁

Steps:

1. Remove the lens from the original fog light (you might need a heatgun to soften the adhesive)
2. Cut out the middle section from the original reflector (we need the bulb holder)
3. Shape it until its round
4. Sand the inside of the print and paint it with shiny mirror finish paint (or electroplate it if you have the means)
5. Test fit it and make four 3mm holes around the perimeter.
6. Clean the surfaces with some Isopropyl alcohol and use some headlight sealant goop to seal the surfaces to prevent moisture from coming in
7. Bolt the holder to the reflector using 3mm countersank screws and some nuts (tighten down until its firm and goop oozes out)
8. Clean the lens and the prints groove with Isoprooyl alcohol and seal them with some goop.
9. Mount it to the car and reconnect the bulb's electrics

Congrats you've got a restored headlight.

How I Designed This

I designed this using Fusion 360 for Personal Use

1. I took all the necessary measurements using my callipers and used some math and my eyeball-o-meter to calculate whatever my callipers couldn't get to.
2. I created a simple sketch that has all the necessary features (like the lens groove and the bulb holder alignment bore) and matches the original reflectors curvature
3. Then I used the revolve function and extruded a 360º cone like shape
4. I used fillets to strengthen some areas like the point where the groove meets the main reflector

Custom Section

Parts and Tools list

Parts:

Headlight sealer
M3 x 15mm countersunk screws 4pcs
M3 nuts 4pcs
Isopropyl Alcohol
Mirror finish paint

Tools:

Heatgun (to separate the lens)
Angle grinder (to cut off the bulb holder and round the metal)
Dril (To drill fixing holes)