Solar Garden Light Repair System – Ø116 mm Base + Modular Ground Spikes

Overview

Give damaged solar garden lights a second life instead of replacing the entire lamp.

The Solar Garden Light Repair System is a modular 3D printable replacement system designed for common round solar garden lights with an outer diameter of approximately Ø116 mm.

Many original solar lights still have perfectly working electronics, solar panels and batteries, while the plastic housing or ground spike becomes brittle, cracks or breaks after prolonged outdoor exposure.

This system replaces these failure-prone parts while allowing you to reuse the original top cover, electronics, battery holder and switch.

The complete set includes a reinforced replacement base and a modular ground mounting system with two interchangeable spike options.

Included Parts

• Reinforced Ø116 mm replacement base

• 4-pin ground mount adapter

• Standard push-in ground spike

• Screw-in ground spike

The modular design allows both ground spikes to use the same 4-pin adapter.

Replacement Base

The redesigned base replaces the damaged original housing while retaining the existing lamp components.

Compared with many thin original housings, the replacement base uses a stronger and more robust geometry designed specifically for 3D printing.

Base Features

• Reinforced replacement housing

• Reuses the original solar light components

• Direct replacement-style design

• Easy access for battery maintenance

• Stable bottom geometry

• Designed for outdoor use

• Sustainable alternative to replacing the complete lamp

Modular Ground System

Instead of relying on a single ground mounting option, the system uses a separate 4-pin adapter with two interchangeable spikes.

This makes it possible to choose the mounting style that works best for the ground conditions.

Standard Ground Spike

The standard spike is designed as a strong replacement for broken or weakened original push-in spikes.

It provides a simple mounting solution for normal garden soil and connects directly to the 4-pin adapter.

Screw Ground Spike

The screw spike provides an alternative twist-in mounting option.

Its threaded geometry allows more controlled installation and can be useful where a conventional push-in spike is less practical.

Both spike designs use the same modular adapter, so the mounting option can be changed without replacing the complete lamp base.

Compatibility

The replacement base was designed around round solar garden lights with approximately the following dimensions:

• Outer diameter: Ø116 mm

• Cover inner diameter: Ø111 mm

• Total lamp height: 30 mm

• Base height: 27 mm

• Pin spacing (opposite pins, center to center): 44 mm

• Pin diameter: Ø6.8–7.0 mm

Solar garden lights that look identical can still vary slightly between manufacturers.

Please compare these measurements with your original lamp before printing.

Printing Recommendations

Replacement Base

• Material: PETG recommended

• Layer height: 0.20 mm

• Walls: 4+

• Infill: 30–50%

• Supports: Yes

Ground Adapter & Spikes

• Material: PETG recommended

• Layer height: 0.20 mm

• Walls: 4+

• Infill: 35–50%

• Supports: No

For outdoor use, PETG or ASA is recommended instead of standard PLA.

Repair Instead of Replace

The goal of this system is simple:

If the electronics, solar panel and light still work, a broken plastic housing or ground spike should not mean throwing away the entire lamp.

Print the damaged component, reuse the working original parts and put the solar light back into service.

The modular design also makes future repairs easier because individual components can be replaced separately.