10th gen F150 Chase Light

Overview

This was one of my very first chase light designs for the 1997–2003 F-150.

Since posting it, I’ve built a lot of different versions, and the one on my truck today looks very different. I’m leaving this older model up in case anyone wants to print it, learn from it, or modify it.

While this is a rough draft design, it has since been updated with more accurate pod and brake light fitment.

If you would like to see my current designs, take a look here.

What This Is

A custom 3D-printed third brake light / chase light housing that installs in the OEM third brake light location on a 1997–2003 F-150 and adds rear-facing chase lights while retaining a factory-style fit.

What You Need

• 2x generic amber LED pods — approximately 1.8" × 3"

• 3x red 3/4" flush-mount LED lights for the brake lights

• 1x white 3/4" flush-mount LED light for the running/cargo light

• Wago connectors or your preferred wire connectors

• 1x switch or switch panel for the amber pods

• 6x countersunk Phillips wood screws — approximately 3 mm × 51 mm (0.12" × 2")

All of these parts, or similar alternatives, can be found on Amazon.

Print & Assembly

The housing is split into three parts because of print bed size limitations:

1. Left tab

2. Center housing

3. Right tab

The left and right tabs attach to the center housing with three screws per side.

I originally used approximately 3 mm × 51 mm (0.12" × 2") countersunk Phillips wood screws. The holes in the model are intentionally slightly smaller than the screw threads so the screws can bite directly into the printed plastic.

The exact screws are not critical, and similar-sized screws should work.

If I were redesigning this version today, I would use heat-set inserts instead of threading screws directly into the plastic, but the current files were designed around the original screw method.

Once the chase light is fully assembled, it aligns with the factory mounting holes on the truck. You’ll want to use shorter mounting screws than the OEM third brake light screws so they don’t bottom out against the cab.

Materials

• ASA — recommended

• PETG — works, but can slowly warp over time from heat

• PLA — not recommended for exterior use due to heat

Designed in Onshape and originally printed on a Bambu Lab A1.

Wiring

• The red brake lights and white running/cargo light can be wired into the OEM third brake light harness.

• Wire the two amber chase light pods to a separate switch or switch panel.

Make sure the lights and wiring you use are appropriate for a 12V automotive electrical system.

Why Leave This Up?

I’ve gone through a lot of versions since making this one, but I decided to keep it available as a free starting point for anyone who wants to print, modify, or learn from one of my earlier designs.

If you want to:

• experiment with it

• remix it

• build something similar

• or just print it and use it

hopefully this gives you a useful place to start.

Please keep this file for personal use.