3D-Printed Fog Light Housings - Ford Mustang Mach 1

I was showing the final result of my Kona N fog light project to my dad one night, when it suddenly dawned on me that his Mustang was the perfect candidate for a similar retrofit! The grille already had cutouts for lights that simply weren't there...yet. My dad agreed to let me design a set of fog light adapter bezels for his Mustang, so I set to work! I first removed his grille and took measurements for clearance, then took a 3D scan of the grille and imported it into OnShape. Conveniently, the grille had removable blank-off plates where the lights would go, so I scanned these and used the fastener locations as datums.

After many iterations, test fits, and tweaking the aim of the lights, the final design was ready. I printed with the same ASA material I used for my Kona shrouds, and they came out beautifully. Finally, I invited my dad over for a Saturday afternoon install session. The final result was stunning. These lights fit perfectly.. it was truly meant to be. Not only do they look fantastic, but they are functional as well! My dad reports that he has been enjoying the additional output in inclement weather.

It was fun to use everything I'd learned from the Kona fog light project to iteratively create a new product in a quarter of the time. I had a great time putting everything together with my dad, and showing him the engineering behind it. This was a true rapid prototyping project, and the end result was phenomenal. Thanks for reading!