A customer came to me with a wild request: create a clean and stylish mounting solution for their Baja Rock Lights. They already had a Wescott Designs modular rack from Get Rigged Co, which was an awesome looking rack with slots for all kinds of custom accessories
I got to work by taking some initial measurement photos and figuring out the rear mounting offset and the ideal bolt diameter. Since the rack was a standard thickness, I chose to work with M5x16mm bolts. (I totally didn't use a bolt I already had a bunch of 🤫)
Thanks to Fusion 360's ability to import images as a canvas, I was able to quickly mock up an initial design.
We settled on a downward angle of about 45° for the mounts, to keep it functional and stylish at the same time I went through several iterations until I found the perfect shape for 3D printing. I started with ABS, but eventually switched to ASA for its longer life and UV protection. These mounts were going to be exposed to the sun, after all!
After getting consistent prints, I snapped a few mock-up photos to share with the customer: