The description and usage instructions are the same as the original version, with some enhancements.
The mounting clips for each headlight of the Ford Transit MK3 (up to 1991) consist of three pieces: two upper clips and one angled lower clip. The angled clip allows for some movement to adjust the headlight screws. Since these clips are no longer available, I decided to recreate them as a faithful reproduction of the original design.
Printing Suggestions:
Print at least two or three clips with different tolerances for the ball joint. The clip should snap in place firmly but without any play, ensuring the headlight is securely held. Too loose a fit might cause vibrations or movement.
Recommended material: PETG, as it offers good durability and easier support removal compared to PLA. If you have access to ASA, ABS, or nylon, feel free to test those and let me know how it works!
Mounting Instructions:
Insert the two upper clips first.
Position the angled lower clip.
Mount the headlight by sliding it from below, aligning it at the top, and securing it with the upper clips.
I printed the clips using a 0.4mm nozzle, 0.2mm layer height, and 90% infill. No brim was used, but supports are necessary (ORGANIC, no snug or other)
The recommended print orientation is the one provided in the image and 3MF file. Specifically:
The clips should be printed horizontally, even though this requires more supports. This orientation ensures greater strength in the direction where it's most needed.
The locking screw can be printed vertically for better threading quality.
These settings and orientations are optimized for durability and proper functionality.
There are two reinforced angled clip versions available. One follows the original dimensions, while the other is slightly thicker at the part that attaches to the metal ball. I printed and installed the thicker version on my Ford Transit.
The angled lower clip now includes a screw with a 10mm head, which can be tightened using a socket wrench.
For a secure fit, apply a small amount of two-part epoxy glue on the screw once everything is working correctly, and then screw it back into the clip.
If you ever need to remove the headlight, simply force it out of the ball joint. To remove the screw, you may need to break the clip and drill out the screw.
Additional Usage Note:
Inserting the clip into the metal ball requires some brute force. Use a sturdy cloth or gloves to protect your hands. Insert the clip as vertically as possible, applying pressure while gently rotating. Be cautious: inserting the clip at an angle could cause it to break under pressure.
Fusion 360 Model Information:
I’ve included the Fusion 360 model for additional customization. Since I used derived operations, you won’t find everything in a single file. If you need to modify the diameter or the tolerances of the ball joint socket, or other geometries, use the main file with the original model. Once you’ve made your changes, remember to update the derived model that includes the screw.
