MACE – LEDs – MACE Project

Exterior

LED Assembly

Instructions

Hand Tools

Materials & Costs

Gallery

Overview & Planning

Assemble LED Mount

Assemble LED Wiring Harness

Install LED Mount

Install LED Wiring Harness

Tools – What’s On The Bench?

Hand Tools

Hand Tools

QTY

Description

^*Soldering iron

^*Solder

Heat gun

Wire cutter

Wire stripper

Sissors

Adjustable wrench or socket

Open barrel crimping tool

^**Side cutter

^**Flat file

^**#22 Drill bit

^**#28 Drill bit

^**Drill

* If self soldering butt connectors are used, a soldering iron and solder is not required.

** Optional, see Assembly instruction video.

Materials & Costs

Required

Item	Qty	Description	Notes	Cost	Sources
Heat Shrink Tubing	7 in	4 mm ID, adhesive-lined	4:1 shrink ratio, glue-lined preferred 8 exterior LEDs require 0.8 meters (2.6 feet) Consider purchasing 2 meters (6 ft) for use with other MACE modules Purchasing 3:1, 2:1, and non-adhesive heat shrink tubing can help save money	$1.20 – $1.90 (per meter)	View
Heat Shrink Tubing	4 in	8 mm ID, adhesive-lined	4:1 shrink ratio, glue-lined preferred 8 exterior LEDs require 0.8 meters (2.6 feet) Consider purchasing 2 meters (6 ft) for use with other MACE modules Purchasing 3:1, 2:1, and non-adhesive heat shrink tubing can help save money	$2.30 – $2.80 (per meter)	View
Heat Shrink Tubing	4 in	16 mm ID, adhesive-lined	4:1 shrink ratio, glue-lined preferred 8 exterior LEDs require 0.8 meters (2.6 feet) Consider purchasing 2 meters (6 ft) for use with other MACE modules Purchasing 3:1, 2:1, and non-adhesive heat shrink tubing can help save money	$3.20 – $4.20 (per meter)	View
DT Deutsch Connector Set	1 set	(1) DT04-2P (male) (1) DT06-2S (female)	Do not confuse with DTM connector DT connectors are rated IP67 (waterproof) DTM is rated IP65 and are not waterproof If ordering a set, ensure the vendor is selling a complete set and not just a single male or female connector Ordering in sets of 5 or 10 is cheater then per set	$1.50 – $1.75 (per set) $9.80 – $10.20 (10 sets or $1.80 – $1.20 per set)	View
Non-Split Closed Wire Loom	16 in	10 mm ID (3/8″) Closed polyethylene tubing	Do not confuse with split tubing commonly found in auto stores 8 exterior LEDs plus the wiring harness around the vehicle may require 17–20 meters (55–65 ft) 10 mm tubing is available in 25–30 meter lengths	$10 – $15 (25 – 30 meters)	View
LED & Waterproof Housing	1	12 mm housing rated IP67 with 3V – 6V DC LED (any color)	IP67: Waterproof up to 1 m (3.3 ft) submersion for 30 minutes Free shipping may not be available on AliExpress, but ordering several brings doen the per item cost Costs approximately $0.80 per unit, with $3.50 shipping	1 pc ~$4.30 inc/shipping 8+ pcs ~$1.22 ea inc/shipping	View #1 View #2
Resister	1	100Ω 1/2W, ±1% Tolerance, Metal Film Resistor	Resistor Options: 220Ω too dim 150Ω acceptable dimming 100Ω good balance of brightness and lifespan (prefereed) Brown-Black-Black-Black-Gold 68Ω optimal brightness, but less lifespan <68Ω (Not recommended)	$1.00 for 20 pcs	View
Thread Locker	1	Loctite, Permatex or equivalent	Loctite 242 Blue or 271 Red (preferred) Permatex blue, orange or red	$5 – $8	View
Silicone Wire	14 in	20 AWG Blue	Blue in the MACE wiring legend represents 5V DC Consider purchasing 20–30 meters (30 m preferred) to complete the wiring for eight exterior LEDs and the harness Eight LEDs require approximately 3 meters (9 ft) of wire The wiring harness requires approximately 17 meters (55 ft)	$9-10 (30 meters 20 AWG)	View #1 View #2 View #3
Silicone Wire	12 in	20 AWG Black	Black in the MACE wiring legend represents negative or ground (0V) Consider purchasing 20–30 meters (30 m preferred) to complete the wiring for eight exterior LEDs and the harness Eight LEDs require approximately 2.5 meters (8.2 ft) of wire The wiring harness requires approximately 17 meters (55 ft)	$9-10 (30 meters 20 AWG)	View #1 View #2 View #3
Silicone Adhesive Sealant	1 tube	Silicone, RTV or equivalent	Do not use caulking Use the most inexpensive option Consider Permatex 80050	$6.00 – $10.00	View

Optional:

Misculanious Items

Item	Qty	Description	Notes	Cost	Sources
Cable Label Display	1	Optional sizes	Sizes: 30 mm x 10 mm 30 mm x 20 mm (preferred) 40 mm x 10 mm 40 mm x 20 mm (preferred)	$3 – $5 (50 pcs)	View
Wire Tie	1-3	– 8 in – black		$2.40 (100 pcs)	View
Self Soldering Butt Connector	3	White/Clear 26 AWG – 24 AWG	Use instead of a soldering iron Solders with a heat gun Eight LEDs require 24 pcs Consider purchasing extra for use in other MACE modules	$1.50 (50 pcs)	View
Self Soldering Butt Connector	3	Red 22 AWG – 18 AWG	Use instead of a soldering iron Solders with a heat gun Eight LEDs require 24 pcs Consider purchasing extra for use in other MACE modules	$1.90 (50 pcs)	View
Coorugated Tube Plug	0 – 16	AD10 (10 mm)	Potentially used on both the LED housing and LED wiring harness	$2.40 (10 pcs)	View
Wire Loom Connector	0 – 8	Corrugated pipe Y joint bellows	AD1 (10mm) AD2 (10mm) AD3 (10mm) Potentially used on the LED wiring harness	$3.90 (10 pcs)	View

Optional:

Universal LED Mount – Round Puck

This mount is designed for use under the front and rear bumper cover.

Item	Qty	Description	Notes	Cost	Sources
LED Mount – Round Puck	1	Typically installed under the front or rear bumper	3D-printed part Requires 15 meters of PLA filament for printing	$1	View
Thread Insert	4	M5 (ID) × 7 mm (OD) × 7 mm (L), 0.8 mm pitch	Also referred to as a Hot Melt Insert If two Round Puck mounts are used on the front and rear bumpers, 16 inserts are needed	$2.50 (30 pcs)	View
Thin Head Hex Screw	4	Size: M5 x 10 mm Pitch: 0.8mm Color: Black Material: Stainless Steel	Sometimes referred to as a wafer head screw 10 mm is the minimum length; longer screws can be used if permitted If two Round Puck mounts are used on the front and rear bumpers, 16 screws are needed Button head screws can be used, but they protrude further from the mount	$1.50 (10 pcs)	View
Flat Washer	4	Size: M5 washer Color: Black Material: Stainless Steel	If two Round Puck mounts are used on the front and rear bumpers, 16 washers are needed	$1.50 (50 pcs)	View
Lock Washer	4	M5 lock washer; color: black Material: stainless	If two Round Puck mounts are used on the front and rear bumpers, 16 washers are needed	$1.40 (50 pcs)	View
Thread Locker	1	Loctite, Permatex or equivalent	Loctite 242 Blue (preferred) Permatex blue	$5 – $8	View

Optional:

Universal LED Mount – L Bracket (long or short)

This mount is designed for use under the driver and pssenger doors.

Item	Qty	Description	Notes	Cost	Sources
LED Mount – L Bracket	1	Typically installed under the driver or passenger doors	3D-printed part Requires 15 meters of PLA filament for printing	$1.10	View
Machine Bolt or Screw	1-2	vehicle and application specific	Size is determined if you are using a preexisting hole, a thread hole, self drilling screw, or a new hole is drilled Zinc or stainless
Flat Washer	4	vehicle and application specific
Lock Washer	4	vehicle and application specific
Thread Locker	1	Loctite, Permatex or equivalent	Loctite 242 Blue (preferred) Permatex blue	$5 – $8	View

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DT04-2P (male) and DT06-2S (female)” image=2363] [twe_product_modal id=”non-split-wire-loom” title=”Non-Split Wire Loom” image=2401] [twe_product_modal id=”led” title=”12 mm LED Housing Rated IP-67, w/3 – 4 V DC LED” image=2408] [twe_product_modal id=”resistor” title=”100 ohm, 1/2 w, ±1% Tolerance Metal Film Resistor” image=2810] [twe_product_modal id=”loctite” title=”Loctite Thread Locker 242 or 271″ image=2449] [twe_product_modal id=”wire-blue” title=”Silicone Wire” image=2652] [twe_product_modal id=”wire-black” title=”Silicone Wire” image=2458] [twe_product_modal id=”silicone” title=”Silicone Adhesive Sealant” image=2462] [twe_product_modal id=”cable-label-display” title=”Cable Label Display” image=2604] [twe_product_modal id=”wire-tie” title=”Wire Tie” image=2509] [twe_product_modal id=”white-butt-connector” title=”White/Clear26 – 24 AWG Self Soldering Heat Shrink Butt Connector” image=2772] [twe_product_modal id=”red-butt-connector” title=”Red 22 – 18 AWG Self Soldering Heat Shrink Butt Connector” image=2771] [twe_product_modal id=”coorugated-plug” title=”Coorugated Tube Plug” image=2822] [twe_product_modal id=”coorugated-y-connector” title=”Coorugated Y Connector” image=2813] [twe_product_modal id=”threaded-insert” title=”Brass Threaded Insert” image=2477] [twe_product_modal id=”flat-hex-black-screw” title=”M5 Thin Head Hex Screw” image=2484] [twe_product_modal id=”flat-black-washer” title=”M5 Flat Washer” image=2487] [twe_product_modal id=”lock-black-washer” title=”M5 Lock Washer” image=2504] [twe_product_modal id=”bolt-screw” title=”Bolt and Screw” image=2527] [twe_product_modal id=”bolt-screw-flat-washer” title=”Zinc or Stainless Flat Washer” image=2541] [twe_product_modal id=”bolt-screw-lock-washer” title=”Zinc or Stainless Lock Washer” image=2538]

Resources

The MACE Project is full of how-to videos, documention, and tips. For a more complete list of the resources offered, vist our Resources section.

3D Printer Files – LED Circle Mount

Edit the Fusion 360 CAD file directly, easily modify parameters and sizes without CAD expertise, or print directly to your 3D printer from a variety of STL files.

View LED 3D Files

Wire Color Standard

The Mace wiring color standard helps identify power, control channels, and communication wires, promoting consistency, easier installation, and improved maintenance.

View the Standard

Mace Project Wire Color Standard

Wire Color	Function
Power
Red	12VDC (+)
Yellow	5VDC (+)
Blue	3.3VDC (+)
Black	0VDC (-) Ground, GND, Battery Negative
Control Channels
White	First
Pink	Second
Orange	Third
Purple	Fourth
Brown	Fifth
Gray	Sixth
Green	Seventh
?	Eighth
Communication
White	TX (Transmit Data) ^*
Blue	RX (Receive Data) ^*

^* TX and RX wires should be twisted together for clear identification or use a bicolor pet braided cable sleeve.

Schematics, Connector Guides & Other Resources

Checkout the LED Resourdes page for helpful tools to complete the exterior LED portion of the MACE Project.

View Other LED Resources

Mace Project Wire Color Standard

^* TX and RX wires should be twisted together for clear identification or use a bicolor pet braided cable sleeve.