Project: Custom TRD Fog Light Covers

Where Can I Find TRD Fog Light Covers?

So, you’ve finally found a Toyota Racing Development (TRD) bumper for your 2000-2005 (7th Generation) Celica! You spent a considerable amount of time searching for one in junkyards, on www.newcelica.org (back before the Facebook group), and on various internet marketplaces. You’ve finally found it, and you go and get it painted/repaired and install it on your car. You step back and look at the new bumper in all its TRD glory and its beautiful. The search has paid off!

But then, after the honeymoon period, you step back and realize, something’s missing. It just doesn’t look complete. That’s when you realize that you can see the ground through your bumper’s fog light holes like some early 2000’s outrageous fiberglass atrocity of a body kit. You pretend that it doesn’t, but it bothers you. You go on the hunt for the extremely rare TRD fog lights and come to find out that IF you can find them, you’re going to be paying as much, if not more, than the bumper itself. Another disappointment.

Alternatives:

• You can install some no-name 4” fog lights from Amazon, eBay, or other Chinese retailer.
• You can go on the hunt for some factory Toyota/TRD fog light covers (discontinued by Toyota).

That is a snapshot of what you can find right now on eBay. Its uncommon to be able to find these, as well, so you end up searching the typical avenues looking for a small plastic covers.

Celica TRD Foglight covers can be found using the typical resources: eBay, junkyards, Japanese auction sites, or here on this website! Wildc4t Workshop is working to reproduce these fog light covers using 3D scanning and 3D printing.

3D Scanning:

Once I was able to obtain a pair of these, I took them to my local University and borrowed their very expensive 3D scanner. I scanned the housings and brought them into CAD to work on.

You can see that even though the scanner is highly accurate and produces a very dense point cloud, there are still holes and noise in the final model. This is typical of 3D scanning, as the technology stands currently.

After some cleanup in Blender and rebuilding the entire mounting mechanism, I had a 1:1 reproduction of the original:

[Re]Production:

These housings can easily be 3D printed; however, since this is a product that will be front and center on the car, I don’t recommend that it be printed on a typical FDM printer. In a pinch, it can be printed that way and post processing can be done to create a nice reproduction, but the best way to produce this is to use resin 3D printing:

Customization:

As shown, I was able to reproduce the part to I high level of accuracy and detail thanks to the processes and tools that I used. However, I wanted to take it further. Since I had the models of these in CAD, I could do whatever I wanted to them, so I thought it would be interesting to add a backlit TRD logo to the covers. Here’s the renderings:

Current Status:

I have been able to make a couple prototypes that are very close to working. I’m still working through some clearance issues that are related to the resin 3D printing process. I am also considering selling the .stl file for the unmodified version if anyone is interested. If you are interested or need help purchasing, comment below or email me at [email protected].

The printed version of the standard fog light cover (shown below) is now available at my store!