Noticed that two of my five 3rd brake lights on my '92 Camaro convertible were out. Pulled the lens unit out and discovered that there aren't really any good LED bulbs in the stock size/socket. You can get clear ones that will kinda fit but without drawings and measurements, it's a crap shoot. Instead I ordered a set of T5 sockets with leads and came up with my mk I design to make them work in the lens housing.

I started with 3D printing a twist-lock adapter to fit in the bulb holes.


Next I managed to squeeze the socket into the plate

 

After several failed attempts and discovering that my slicer was rounding the dimensions up on my imported STL files I got the adapters to fit snugly into the housing openings.


I then printed some backer bars to hold the lights into the housing. My printer wasn't big enough to print a single piece so I broke it so that there were two screw holes in each half.

 

The square holes hold the lamp sockets so that the LEDs on the side point at the widest part of the reflector.


Here's where I've got it to this morning. The retainer bars are a bit chonky and I'm not certain that the screw holes line up exactly. My worry is that the housing screw holes are going to be brittle. I've designed everything so that I can return it to stock but am thinking I may have to reinforce the housing studs with epoxy or something to make it work.


I'm thinking that my mk II version will incorporate the adapter plates, have a stop for the twist-lock so the LEDs orient the right way, and extend the adapter a little above the housing to allow for a viton rubber o-ring.

 

Very interesting. Looking forward to seeing them installed.

 

Went out to the arctic conditions in the shop and, with the use of a 1/8th drill bit, was able to clear out the screw holes. Two of them needed slight "wallerin'" but all the screws went in with finger pressure so I snugged them down and everything is nice and stable.

I forgot to take a picture before I commenced the wiring. sorry! All they need is the heat gun to seal up the shrink tubing, a few zip ties and plugging them in.
I found a paperclip with the same size as the pins in the original bulb socket tray and cut me a couple of leads. I'll put some shrink tubing over the connector to hold the wires and protect the connection.
Final test before I seal it all up and install it.


I tested at high alternator voltage just to make sure I don't blow out a bulb.
A quarter amp is like 20x less current than the three good incandescent bulbs pulled when I put them on the PSU.
I'll try to get a photo in the car but it's raining like crazy right now.

 

Just curious if I sent you one, would you be willing to make another?

 

I'd be happy to do so. There are a few caveats:
1. I'm using PLA plastic which has a melting point of 180 C (350 F) and don't know what the characteristics are below freezing.
2. My paperclip connector didn't work out so swell so I'm just using the solder-tinned leads to plug into the connector.
General disclaimer:
I'm not a professional. My modeling skills are rudimentary so the fit and finish may not be what you expect. I had to use a wood rasp to grind off a bit of the ends of the backer because they interfered with the mounting screw tabs in the spoiler.

Are you interested in the mk I design or do you want to wait for my mk II design? I'm looking to make the bulb adapters and the backing plates single units to allow the addition of an o-ring.

 

I'll PM you later and we can work out the details (plus, I need to find my spare spoiler anyway). As far as what they'll do below freezing, , I live in Ventura County, SoCal. If it dips into the 40's we freak out. I'm patient and this is just a nice-to-have, not a need so there's no rush on my end. I can wait till your next design if you think it will be better. If it needs some minor adjustments I'm capable and own a couple dremmels and files if needed.

Eldon

 

Sounds good! I'll let you know by the end of this weekend. We haven't gone above 45 degrees as a high for the last couple of days. I miss the California weather this time of year.

 

Very cool. I'm interested in this too. Car is getting ready to be down for a bit though, so I'm no hurry at all. I'll probably PM ya some time in the future! Nice work.

 

Anybody have a part description/number for this connector?
Standard Motor Parts has the S-1611 which is the right housing but uses male blade connectors rather than pins.
I found the female version of this in my spare '97 Blazer dash harness but don't have the item it plugs into attached. This matches the connector in the spoiler for the 3rd brake light.

 

Only marking on it is the usual P.E.D and 14 which the arrow is pointing to, voreteciroc would be the one to ask.

 

That Connector Body is still Active/ Available (NOT for long though)...

Delphi Metri-Pack 150 UnSealed Male Two-Way Connector:

-Body = 12047663
-TPA = 12047665
-Terminals = 12047581

Mating Connector:

-Body = 12047662
-TPA =15324070
-Terminals = 12047767

 

Thank you! This completes the BoM for my build. Now I guess I have to get going on Mk II.