As part of an ongoing restoration project of a 1986 Alfa Romeo Spider, I fitted a replacement spoiler with custom designed brake lights.
Initial Removal and Deconstruction:
The original spoiler had been on the car since it rolled out of the factory in 1986 and as such the factory adhesive had hardened beyond the scope of normal removal methods.
Custom Removal Wedge
In order to get enough leverage to pry up the old spoiler without damaging the paint on the trunk lid I decided to design my own wedge. I first designed the wedge in Solidworks and then 3D printed it in ABS plastic.
Installing Spoiler Replacement:
With the difficult step of removing the old spoiler out of the way, I was easily able to install the new spoiler using a much higher quality 3M adhesive.
3D Printed Brake Light Iterations
In order to achieve a proper fit with the compound angles on the new spoiler I went through several prototypes while slowly dialing in the exact fit. In order to mount the new brake light without requiring visible screw heads I chose to design my part to include embedded nuts which allow screws from the back to mount the brake light housing to the spoiler.
Wiring:
To simplify the wiring and light source choice, I opted to purchase premade trailer lights and remove the LEDs, solder them together, and attach them to my cars existing brake light wiring using screw terminals.
Final Installation and Testing:
After wiring in the new brake light and securing the 3D printed housing I was able to see the final look of the new spoiler with an illumined brake light.
