When we started this project, we already new that we were going to change the front side/indicator lights on our MX-5e. Ethan fitted the Jass Performance Stealth TSI units to Yoko and these sit further back, recessed into the bodywork. We think they look better like this and these lights work really well. With the MX-5e, we want something similarly subtle but also a bit more futuristic looking.

We looked at numerous LED upgrade options but they were all really expensive. We particularly liked the style of these Carbon Miata Sequential LED Turn Signals but, we are not fans of sequential indicators.

We are looking to replicate this style of light but, with solid oval bars that light up white or orange. Whilst the indicator is in operation, the white side light will be off. Our plan is to configure these lights so that the white part is used as daytime running lights, intelligently controlled by the Driver Control Unit (DCU). They will also work like regular side lights if they are switched on.

Carbon Miata do a tinted version that would suit our MX-5e nicely. They come with the in-built resistors, to keep the flash speed correct but this is not an issue as we are rewiring the car with a digital (fixed rate) flash unit.

We mocked this photo up to see what they would look like with the electric blue paintwork we have planned 😎

We also like these IL Motorsport LED lights.

We did some analysis of the standard light unit and it has a complex surface profile, to sit flush with the aperture in the bodywork. Fortunately, a recessed light unit like the ones used on Yoko has a curve in just one plane. This makes them much easier to model and 3D print.

We completed an initial design in Autodesk Fusion 360 for the left side light (they are not symmetrical), which we then 3D printed. This allows us to check our measurements match the reality of the bumper aperture. This was a 3½ hour print.

This first print showed us that we need to do some tweaking to our design to get a nice snug fit. In retrospect, we should have gone with a much simpler test print and later ones were much simpler. We have done five now!

As of March 2024, we are working with this symetrical 3D printed module, which uses ultra-bright, clear 5mm LEDs. White ones around the outer edge and orange ones in the middle section. These will be encapsulated in a tinted expoxy resin which will also diffuse the light slightly. We have fitted mounting tabs that can be used with brackets and the existing mounting holes. This modular design means we can develop and test the "bulb" part of our design quickly and cheaply. Each 'light module' costs about £6 in parts.

We have also designed a PCB to make it easier to construct the light units, using 5mm ulra-bright LEDs and our PWM lighting unit.

The PCBs cost about £6 to get five made and delivered.

The LEDs are quick and easy to solder.

Our experiment with Perspex worked well but, the tint was far too dark. It does look very cool though 😊 We are going to try again with a 901 neutral tint and a 3D printed LED housing behind it.