Lukas Gill
Project 03

Miata Parts

No.03
CategoryVehicle components
ClientSelf-directed
RoleDesigned + manufactured, all parts
Base1990 Mazda MX-5 · Rocket Bunny
Process3D scan · surface model · print · finish
Year2022 - Present

An ongoing set of components for one car. Every part here was designed and manufactured by me. The brief I set myself was to modernise where the original design language allowed it and leave it alone where it did not, so each part had to sit next to thirty-five year old bodywork without feeling out of place.

The rear end of the vehicle was 3D scanned and reverse engineered to design fully custom three-bulb taillights and a ducktail spoiler, both printed, smoothed and painted to a fitted finish. The door handles were surface modelled around a linear-actuator popping system, so a button press replaces the original pull while keeping close to the original shape language.

Inside, a 2.1 audio system with printed eyeball vent tweeter pods, a period-correct digital audio visualiser and cubby system, Alcantara door cards with door pullers, and window winders. A MagSafe wireless charger takes the space of the ashtray, offering 20 W charging powered straight from 12 V. HVAC panel, knobs and sliders, and a removable cup holder system.

Printed brackets and surface modelled surrounds fit rectangular 4x6 headlights behind the pop-up mechanism. The pop-ups are run by a four-layer PCB I designed around an STM32C0 with automotive high-side switches, replacing a thirty-five year old fixed relay and prototyped on a breadboard Arduino and relay setup. It drives from the factory switch: one click toggles, two winks, a long hold forces both down.

Eli Crawford contributed to the ideation of the ducktail spoiler and did much of the modelling on the taillights.

The designed Miata parts arranged on a galvanised rack, with the door panel alongside
Miata Parts360° - drag to rotate

Front

Door handles, 4x6 conversion
Front end
Front endRender
Door handle v6.0
Door handle v6.0Render
Door handle v6.0, rear
Door handle v6.0, rearRender
Headlight surround
Headlight surroundRender
Headlight surround
Headlight surroundRender
Door handle v6.0, installed
Door handle v6.0, installedInstalled
4x6 conversion
4x6 conversionPhotograph
Front progression · 11 photos · view all

Rear

Taillights + ducktail
Rear end
Rear endRender
Taillights
TaillightsPhotograph
Taillights
TaillightsPhotograph
Ducktail
DucktailRender
Ducktail
DucktailRender
Ducktail
DucktailRender
Rear progression · 30 photos · view all

Interior

Charger, tweeters, cubby, controls
Visualiser + cubby
Visualiser + cubbyPrinted
Tweeter pod
Tweeter podPrinted
Wireless charger v5.1
Wireless charger v5.1Printed
HVAC panel
HVAC panelPrinted
HVAC panel, detail
HVAC panel, detailPrinted
Wireless charger v5.1, alternate
Wireless charger v5.1, alternatePrinted
Tweeter pod, parts
Tweeter pod, partsPrinted
Visualiser + cubby, alternate
Visualiser + cubby, alternatePrinted
Interior progression · 23 photos · view all
Front11 photos
Door handle, CAD01 · Door handle, CADDoor handle, CAD02 · Door handle, CADDoor handle, CAD03 · Door handle, CADDoor handle v5.4, installed04 · Door handle v5.4, installedDoor handle v5.405 · Door handle v5.4Door handle v5.406 · Door handle v5.4Door handle v4.107 · Door handle v4.1Door handle v4.108 · Door handle v4.1Door handle v309 · Door handle v3Headlight, fitted10 · Headlight, fittedWiper spoiler11 · Wiper spoiler
Rear30 photos
Fitted, rear01 · Fitted, rearFitted, rear02 · Fitted, rearFitted, rear03 · Fitted, rearTaillight in final primer, one in paint, spoiler in filler04 · Taillight in final primer, one in paint, spoiler in fillerFiller + sanded, taillights and spoiler05 · Filler + sanded, taillights and spoilerPainting, taillight06 · Painting, taillightPainting, reviewing the work07 · Painting, reviewing the workTaillight, first install of painted lens08 · Taillight, first install of painted lensTaillight, painted, complete09 · Taillight, painted, completeTaillights, lit, complete10 · Taillights, lit, completeTaillight surround, CAD11 · Taillight surround, CADTaillight surround, CAD12 · Taillight surround, CADTaillight surround, CAD13 · Taillight surround, CADDucktail, CAD14 · Ducktail, CADDucktail, CAD15 · Ducktail, CADDucktail, CAD16 · Ducktail, CADSpoiler test print, printing17 · Spoiler test print, printingSpoiler test print, on print bed18 · Spoiler test print, on print bedSpoiler test print, in hand19 · Spoiler test print, in handSpoiler test print, on car20 · Spoiler test print, on carSpoiler test print, on car21 · Spoiler test print, on carSpoiler test print, on car22 · Spoiler test print, on carTaillight, first print, fitment check23 · Taillight, first print, fitment checkTaillight, first print, fitment check24 · Taillight, first print, fitment checkTaillight, early test print, fitted with lights on25 · Taillight, early test print, fitted with lights onFitted, rear, early two-piece test print26 · Fitted, rear, early two-piece test printSize comparison between iterations27 · Size comparison between iterationsTaillight, early CAD, scan28 · Taillight, early CAD, scanTaillight, early CAD29 · Taillight, early CADSpoiler, early revision, scan30 · Spoiler, early revision, scan
Interior23 photos
Interior, fitted01 · Interior, fittedTombstone fitted: tombstone, HVAC, knobs, cubby02 · Tombstone fitted: tombstone, HVAC, knobs, cubbyWireless charger v5.1, CAD03 · Wireless charger v5.1, CADWireless charger v5.1, CAD04 · Wireless charger v5.1, CADWireless charger v5.1, CAD05 · Wireless charger v5.1, CADWireless charger v5.1, rear electronics06 · Wireless charger v5.1, rear electronicsWireless charger v4.207 · Wireless charger v4.2Wireless charger v4.208 · Wireless charger v4.2Wireless charger v4.2, fitted09 · Wireless charger v4.2, fittedWireless charger v4.2, detail10 · Wireless charger v4.2, detailWireless charger v211 · Wireless charger v2Shift knob and e-brake handle, CAD12 · Shift knob and e-brake handle, CADDoor card installed13 · Door card installedDoor card, finished detail14 · Door card, finished detailDoor card, pattern cut15 · Door card, pattern cutWinder handle, finished16 · Winder handle, finishedCup holder, in use17 · Cup holder, in useE-brake handle, turned, before parting off18 · E-brake handle, turned, before parting offHazard and pop-up buttons19 · Hazard and pop-up buttonsHazard and pop-up buttons20 · Hazard and pop-up buttonsCubby, in hand21 · Cubby, in handCubby iterations22 · Cubby iterationsTweeter pod, disassembled, wiring23 · Tweeter pod, disassembled, wiring