When i was changing lights in my car and went to reach for the license plate light, i just felt wires, then felt rusty metal crumble onto my hand. Then i pulled out this crap.

I tried to rig it up with zip ties and wire, but it didnt work, so i knew i had to fix it quick. I searched and found the part online for $50. I ordered it and when i got it i wasnt really surprised how simple of a part it is for $50, but i knew i could easily replicate the function out of scrap metal.

Since ive been wanting to practince with Solidworks Sheet metal, i figured this is perfect.

I started by modeling the purchased part in Saladworks. I noticed that it is made from two separate sheet metal parts, welded or sandwiched together.

I realized that the only function provided by the part i colored green, is to make the grey part more rigid. I figured it would be much simpler to just add some rigidity to the functional part.
I added the vertical flanges to make the part more rigid. This was very necessary since i planned on using thin aluminum.

Next was to use the Sheet metal feature called “Flat Pattern” which converts a sheet metal part to a 2D layout that can then be cut and folded out of sheet to make the part

I went to the scrap metal store and found some 14 guage alumium. I grabbed a sheet of stainless just incase. $5 for the sheets and a couple extra scrap pieces for welding practice.

I Printed out the Flat Patter in real size. I cut it out and taped it on a sheet of aluminum. I started trying to cut it with shears, but it was kind of difficult, and i figured i would have to sand the edges and dremel out the pockets anyway. So i ditched the shears and just used a cut off wheel on the dremel to cut along the lines.

Flat Pattern Cut Out

The Bending was not bad. The hardest part was the short long support ribs. They’re hard to get a grip on to fold, and its a big tab with a lot of aluminum. I made a smart move and did those first, since i would have a flat sheet to put in a vice and hold.

The part turned out great. It cost about 99% less than OEM. It fits and works prefectly.