A fellow car enthusiast approached me and asked if I could create a set of LED tail lights for his Volvo. Having worked with automotive LEDs in past I was up for the challenge. The idea was simple, take a set of 01-04 stock Volvo S60 tail lights and retro fit some LEDs in the housing to replace marker, brake and also turn signal bulbs!

So we started with a conceptual design…

I then began to create the CNC program that would create the circuit board to mount the LEDs thereto…

This resulted in sucessfully CNC cut circuit boards that fit the contours of the tail light housings…

Test fit the cut circuit boards in the tail housings…

With the boards cut, it was time to populate them with the LEDs & resistors…

And then a test fit of the main section of LEDs running…

The LEDs need a controller to run them and to switch from marker to brake mode, so I made a quick cover for the project box which houses the controller…

After populating the turn signal circui boards, I bench tested them…

After mounting the boards in the housing and sealing the lenses back onto the housings, I bench and stress tested the LEDs…

The finished product!