The Quick and Easy Rear Bumper LED Cube Retrofit

TiN

New member
ORDERING INFO:
Send me a PM with your name and address.

Pricing:
$30 - 1 unpainted pair; includes shipping in US

1 pair takes 12 hours to print, so I will be send you a PM involving the payment as your selected items become available to ship.


ORIGINAL POST:
For the last few weeks, I have been developing a way to easily mount LED aux. lights in the rear bumper of '03-'05 T4Rs. The design was largely inspired by the work of Gaterose and others, as well as my own experience with retrofitting LED cubes in the past...

I hope to have these available for purchase on Shapeways as soon as possible. However, they are a work-in-progress for the time-being.

The Goal:
Create a 1 piece LED mounting system that requires minimal cutting, doesn't require removal of the rear bumper, and uses the existing bumper reflector housings.

The Solution:
Through the use of the SuperbrightLEDs 10W 2" Work Light (The same unit that I custom-mounted in my recent headlight retrofit), I was able to design a one-piece replacement reflector lens (filler plate) that also serves as a mounting point for the LED.

Installation is easy:
  1. Unbolt reflector housings from bumper
  2. Detach the reflector lens using normal lens-baking methods
  3. Drill 22mm hole into back of reflector housing (where a bulb would appear to go)
  4. Mount LED cube to replacement filler plate using included hardware
  5. Re-attach filler plate to reflector housing using strong adhesive/silicone (I'm not sure if the reverse baking process will be possible with 3D printed filler plate)
  6. Bolt into bumper, wire up, and use!

Prototype Pictures:
(In the printed models, the orange part represents the LED cube while the blue part represents the filler plate/mounting system)
LEDCubeReflectorPlate_zps5dc827a7.jpg~original

IMG_4455_zps5f76cf69.jpg~original

IMG_4456_zps288cbf11.jpg~original

IMG_4457_zps491f85ed.jpg~original

IMG_4458_zps4a1406c5.jpg~original
 
Last edited:
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I am interested in seeing how this finished product turns out. Thank you. I have been wanting to do something like this in that spot
 
You're making me jealous for not owning an older 4th gen. This looks nice, can i ask how you got the perfect shape for it? Seems very well designed
 
You're making me jealous for not owning an older 4th gen. This looks nice, can i ask how you got the perfect shape for it? Seems very well designed

For the main curvature, I took a 2D scan of the profile of the housing and traced it in Solidworks. Then I used a Lofted Extrude feature in Solidworks to make it a solid. I'm really happy with the fitment, since it is such an organic shape.
 
For the main curvature, I took a 2D scan of the profile of the housing and traced it in Solidworks. Then I used a Lofted Extrude feature in Solidworks to make it a solid. I'm really happy with the fitment, since it is such an organic shape.

Do you have access to a 3D printer, or are you using a service?

If using a service do you mind sharing which one?
 
watching!. [MENTION=100305]TiN[/MENTION] love your headlights, have you considered doing for forum memebers?..if yes..how much would it cost
 
Do you have access to a 3D printer, or are you using a service?

If using a service do you mind sharing which one?
I have two home 3D printers that I use for prototyping, but the final product will be printed by Shapeways.com
 
watching!. [MENTION=100305]TiN[/MENTION] love your headlights, have you considered doing for forum memebers?..if yes..how much would it cost
I've considered building a few more sets identical to my headlights. I would need to figure out exact costs, but it would probably be around $800 per set including new aftermarket housings.
 
So I've finished designing and printing what I believe will be the final version of my filler plates. Soon, I'll be ordering the lights to make sure everything fits correctly. If all goes well, I'll then order a pair from Shapeways to put on my T4R.

For those who are interested in a set for themselves, there are a few ways we can go about this.

  1. Have them printed on my home printer in black ABS plastic. (Cheapest option @ about $50.00/pair; lowest surface quality)
  2. Have them printed by Shapeways. (More expensive @ about $100/pair; better surface quality and durability)
  3. Build a preorder list and have them injection molded. (Needs large amount of interested buyers to be reasonably priced; best surface quality and highest durability)

IMG_4571_zpsnzkrcgft.jpg~original
 
So I've finished designing and printing what I believe will be the final version of my filler plates. Soon, I'll be ordering the lights to make sure everything fits correctly. If all goes well, I'll then order a pair from Shapeways to put on my T4R.

For those who are interested in a set for themselves, there are a few ways we can go about this.

  1. Have them printed on my home printer in black ABS plastic. (Cheapest option @ about $50.00/pair; lowest surface quality)
  2. Have them printed by Shapeways. (More expensive @ about $100/pair; better surface quality and durability)
  3. Build a preorder list and have them injection molded. (Needs large amount of interested buyers to be reasonably priced; best surface quality and highest durability)

IMG_4571_zpsnzkrcgft.jpg~original

Looks good. If I did it I would go with the cheap route, sand them down some then paint them to match the bumper. I'm also wanting to Line-x the outside of my truck, so the roughness wouldn't bother me one single bit. Would be cool to have an easy mount for some nice bright offroad backup lights! Keep up the good work man!
 
Inspired by [MENTION=101553]t-man[/MENTION] , I decided that the best route for me would be to print the filler plates myself and paint them... I used 3 layers of filler primer and 4 light layers of Duplicolor Bedliner spray to achieve this look. It came out much better than expected; can't even tell it was 3D printed!

That being said, I think I'll offer these through my own printing services only, as that is easily the most affordable option for anyone who wants them. Pricing for painted and unpainted parts will be up soon. Production will begin when I finish my pair and ensure that the fitment is spot-on.

For those who know they'll be interested, shoot me a PM so I can get an idea of how many I'll need to print initially. The first members to PM will be the first ones to have their orders filled.

IMAG1535_zpss4utqah8.jpg~original
 
Inspired by [MENTION=101553]t-man[/MENTION] , I decided that the best route for me would be to print the filler plates myself and paint them... I used 3 layers of filler primer and 4 light layers of Duplicolor Bedliner spray to achieve this look. It came out much better than expected; can't even tell it was 3D printed!

That being said, I think I'll offer these through my own printing services only, as that is easily the most affordable option for anyone who wants them. Pricing for painted and unpainted parts will be up soon. Production will begin when I finish my pair and ensure that the fitment is spot-on.

For those who know they'll be interested, shoot me a PM so I can get an idea of how many I'll need to print initially. The first members to PM will be the first ones to have their orders filled.

IMAG1535_zpss4utqah8.jpg~original

I like it! Very rugged looking, will fit and blend in especially for anyone with a lifted and built truck. Good choice in my opinion! I will get a set from you in spring as money is TIGHT in the winter up here.. ugh I already have lights that will fit in there on the front of my truck, I want some spots up there with the 1 set of floods instead of 2 sets of floods.
 
Here's a quick update:

I'm getting very close to being finished with these. I tweaked the design a bit, printed both LH and RH sides, and now I am painting/assembling.

Some pictures of the right side filler plate after being sprayed with bedliner and mounting the LED cube:

IMAG1561_zpsaf3qfs1z.jpg~original


IMAG1563_zpsvysbbdwx.jpg~original


IMAG1565_zpsd2cvelnk.jpg~original
 
Here's a quick update:

I'm getting very close to being finished with these. I tweaked the design a bit, printed both LH and RH sides, and now I am painting/assembling.

Some pictures of the right side filler plate after being sprayed with bedliner and mounting the LED cube:

IMAG1561_zpsaf3qfs1z.jpg~original


IMAG1563_zpsvysbbdwx.jpg~original


IMAG1565_zpsd2cvelnk.jpg~original


looking good!
 

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