Evora Magnetic Trickle Charger w/ LED plate lights

thingiverse

This collection of things replaces the stock license plate festoon light fixtures on all Lotus Evora models, and integrates a magnetic trickle charger connection. The LED COB lighting is significantly brighter than OE incandescent or traditional LED festoon bulbs. This may work on Lotus Elise and Exige models too with some modifications. The complete assembly is a mixture of FDM and resin printed parts, along with some hardware noted below. Print 1 of each, except where indicated: - evora_mag_chrg_top_mag - evora_mag_chrg_top_nomag - 2x evora_mag_chrg_ledcover - print in clear resin - 2x evora_mag_main_contact_fitting - print in black resin (or color of your choosing) - evora_mag_chrg_plug_body - evora_mag_chrg_plug_cap - evora_mag_chrg_plug_dust_boot - print in TPU Hardware needed: - 2 sets of 10mm waterproof magnetic pogo contacts (total of 4 pieces) - choose the 5A rating at a minimum - 6.3mm spade crimp connectors, male and female (2 sets) - 6.3mm spade crimp connectors, male x4 - 2x crimp ring terminals (blue, 14-16awg) - 1x inline fuse holder w/ 10A fuse - White COB LED 12V strip, with cut lines no more than every 25mm apart - 22awg wires for LEDs - CA adhesive (otherwise known as Krazy Glue) - 3M DP270 black potting compound - Misc sizes of heat shrink tubing - 6.5 feet of 16awg 2-conductor parallel wire, silicone insulated Assembly: Solder a small length of 16awg wires onto 1 set of magnetic contacts and shrink wrap over the joints. Place inside one of the contact_fitting parts, ensuring the male and female pieces match the orientation you desire. Tack in place using a bit of CA glue. Slide that assembly into the bottom of evora_mag_chrg_top_mag, aligning the flat with the closest flat edge. Tack in place with a bit of CA glue. Strip ends of these wires and crimp on 1 set of spade connectors (male/female). Fill the contact_fitting with potting compound and set aside to dry. Measure and cut 1 length of LED strip, 2 segments long (the width of the angled mounting pad). Solder 2 22awg wires to LED strip and insert wires through the printed body. Strip ends of these wires and crimp 2x male 6.3mm spade connectors and cover ends with heatshrink tubing. Using a 12v source, test the LED to ensure it works prior to the next step. Place a dab or 2 of potting compound around the base of the LED wires as it exits the back of the fixture and set aside to dry. Once the LED is tested, remove adhesive liner from back and adhere to the angled mounting pad. With your potting compound, run a very small bead around the circumference of the LED area in the "trench", and place one of the clear resin evora_mag_chrg_ledcover pieces over it (the angles should match). Using a small clamp, hold the lens cover down until the potting compound sets. Repeat the previous steps involving the LED on the evora_mag_chrg_top_nomag part. Solder a small length of 16awg wires onto the other set of magnetic contacts. Place inside the other contact_fitting parts, ensuring the male and female pieces correspond to the ones within the evora_mag_chrg_top_mag part. Tack in place using a bit of CA glue. Slide that assembly into the bottom of evora_mag_chrg_plug_body, aligning the flat side with the flat side internal to the plug body. Tack in place with a bit of CA glue. Fit the evora_mag_chrg_plug_dust_boot over the wires. Fill the body of evora_mag_chrg_plug_body with potting compound, and place the evora_mag_chrg_plug_cap on the bottom. With the remaining 16awg wire (about 6 ft), strip both wires on one end and crimp the matching 6.3mm spade connectors on, and on the other end, strip both wires and solder the inline fuse holder on the red/positive wire, and crimp the ring terminals to both ends. Run the spade connector end of the wires through the grommet that also contains the rear view camera cable, and fish out through one of the license plate light holes. Connect to the evora_mag_chrg_top_mag part, matching polarity and connector gender. Attach the ring terminals to the battery. Solder or crimp your evora_mag_chrg_plug_body onto your trickle charger cable, ensuring polarity is on the pin/wire you expect it to be. UPDATE: Added a few new parts for an updated version that uses a TPU-printed gasket, and a different LED lens cover design that's held on by M2x8 socket head screws w/ washers, and M2x4 threaded inserts. The lens is much easier to resin print and is less likely to crack during removal. It's been pre-scaled down, as most resins have a certain amount of expansion (or shrinkage) during curing. I print mine scaled at 103% and the dimensions come out perfectly. UPDATE 2: Added new bodies for S2 vehicles (Evora 400, GT, etc.) as the plate light finisher is different from the S1s (the lights are set further back, closer to the bumper). Thanks to WaterLily for helping resolve fitment/clearance issues! The S2 parts use the same gaskets and LED covers, but the mag charger body is longer on the vehicle side.