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| Crumbling 3rd brake light housing (Page 1/1) |
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ThatRickGuy
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JAN 02, 01:05 AM
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While replacing my headliner, my 3rd brake light housing started falling apart. Both of the tabs for the mounting bolts crumbled, both tabs for the cover mounts are cracked and ready to fail. The bulb has melted a huge divot into the bottom of the housing. Luckily, I also have a 3-d printer, so I started working on a replacement. First draft was close, but having it on my desk where I could compare it to the remains of the original I was able to make a bunch of refinements. v2 is on the printer now. If I can get it to be a bolt-in replacement, I'll toss the STL up on Thingiverse, but I'd recommend using ABS or some other higher heat material if you're planning on sticking with the stock bulb, that thing gets HOT!
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Frenchrafe
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JAN 02, 07:02 AM
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Yeah, I've had this kind of plastic decomposition as well.
I just use epoxy putty to remake the missing pieces; it glues well to most ABS type plastics.------------------
"Turbo Slug" - '87 Fiero GT. 3800 turbo. - The fastest Fiero in France! @turboslugfiero
https://youtu.be/hUzOAeyWLfM
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ThatRickGuy
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JAN 02, 12:00 PM
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Original with a new LED light:
v2 with the LED light, unpainted:
All the bolt holes matched up, but it's ~1/8th inch thicker, so I need to trim it up a bit. Then onto the actual light hole and the side retainer clips.[This message has been edited by ThatRickGuy (edited 01-02-2024).]
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ThatRickGuy
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JAN 03, 12:27 AM
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Good news is that revision 3 is almost perfect. Bad news is that I just can't get this headliner back up. I picked up the ABS headliner from the Fiero Store, and it's lined up perfectly with all the other holes. But the back in the middle hangs low. Both coat hooks are up and snug, but towards the middle it sags a good inch plus and there's no way the trim piece on the 3rd brake light is going to hold it up. Especially on the passenger side where the third brake light wire is, I have to push hard to get that side up to where it needs to be. Anyone work with these headliners have any pointers?
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ThatRickGuy
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JAN 06, 05:03 PM
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Way more "fun" than I was expecting. The stock wiring harness for the 3rd brake light protruded too much for the ABS headliner to sit flush:
So I fished it through the frame instead. Had to pop off the plug first, but after that it was just like pulling wire anywhere else.
Headliner took a bit more trimming around the 3rd brake light, but went back in and sat flat!
And the new LED brake light housing came out almost perfect. I had to trim the tab reinforcements just a tad, I had neglected to account for the weird washer-heads on the bolts.
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ThatRickGuy
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JAN 06, 05:19 PM
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82-T/A [At Work]
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JAN 09, 07:57 PM
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This is too awesome! Is this the file I need for my 3d Printer so I can print my own? I just bought a decent 3D printer, and haven't made anything other than the test items that are already on the SD card it came with. I didn't even see what file extension it had on it. This would be so cool if I could print my own part!
Thank you!
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ThatRickGuy
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JAN 10, 12:00 PM
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Yup, this is the .STL file. You'll need to run it through a Slicer before you can print it. For FDM printing I use Utilimaker Cura. For SLA printing I wind up using a few different tools, typically prusa for supports, 3dbuilder (included in Windows) to fix meshes (it auto prompts and does it), and then the manufacturer's recommended slicer depending on the printer.
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theogre
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JAN 11, 12:27 AM
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| quote | Originally posted by ThatRickGuy:
I'd recommend using ABS or some other higher heat material if you're planning on sticking with the stock bulb, that thing gets HOT! |
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Printed ABS etc won't long w/ OE bulb either. OE part should have ABS etc near PN & other marks on them.
I don't know why GM use 889 27w bulb because no room to have the very Hot bulb there. Nothing I know of has very hot bulb in High Brake in other models. Many use 1 2 or 3 standard tungsten bulbs in about same size fixture & lens. Even Cyclops that is bigger then Fiero High Brake & other aftermarket high brake uses standard bulb(s).
Also many "books" list 906 (12v 9w) for Fiero High Brake that no Fiero have used. www.sylvania-automotive.com & others have same info...
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Dr. Ian Malcolm: Yeah, but your scientists were so preoccupied with whether or not they could, they didn't stop to think if they should.
(Jurassic Park)
The Ogre's Fiero Cave[This message has been edited by theogre (edited 01-11-2024).]
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