light bar build, take 2

badoosh27 · 05-10-2009, 01:19 AM

The last light bar i built for my 01 TJ ended up being destroyed in my rollover, so it's time to rebuild. The original one was a 1.5" x 1.5" square aluminum tube 48" long with 4 Hella FF75's attached to the front. I didn't really like this because it stuck out too far in my opinion. This time around, i wanted them recessed where only the lens was visible. I found these work lights at Northern tool:http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_352681_352681 that are 5"x1.75" and seemed small enough to fit into some kind of square tube.

The next part is the tube. I went to Lowes and was looking at the stock metal and it's all fairly high, me being very very frugal, so i moved on. Out in the garden section i found parts for fences and low and behold, there's a square tube. It's 2" square and almost 7' long and only $14 to boot. it's not flimsy stuff either, maybe 12 gauge steel? i dont know, but it's hefty and it came with end caps!!

Now, how to mount to the jeep? On the last one, i used stainless steel brackets that i made myself, but now i don't have any stainless, so i got galvanized. They are pieces about 8"x4" with a bunch of holes in them for joining boards together for framing. I'll bend them in half to match the angle of the windshield and use self tapping screws to mount to the surround above the windshield, same as last time around.

I already have wiring to my switch panel for 2 more switches, so i just need to get relays and i already have the wire itself too. my plan is to have 6 lights all together, so i can have one switch for four, and one for 2.

My next hurdle is how to cut the holes. I have them measured out using masking tape to mark the center lines and i'm going to cut a template out of plexi-glass, but i haven't quite figured out how to cut the holes in the steel. I think i'll use my dremel, but i dont think my apartment neighbors will like that... any ideas? they aren't squared holes either, the ends have slight rounds to them.

I know this is a lot to read, but i figure if someone wants to copy me, it's best to have as much info as possible. I'll try and post pictures tomorrow, but it is mothers day, so i dont know if i'll have time, but there will be pix soon. thanks for reading and leave some feedback

badoosh27 · 05-10-2009, 10:54 PM

here's some pictures for yall.

the tube (fence post):

the spacing. the blue tape is the center line of the lights except for the one in the center and the one at the end where i'm cutting it

and heres what it will look like when they're installed, hopefully:

here's a pic of the original light bar, well after the rollover jacked it all up:

**SHAKEnBLAKE** · 05-10-2009, 11:49 PM

^^ ballin! I like this.

Are those lights going to fit? It looks like the tube may be a tad too narrow.
The site says that they're 4 inches deep? Are you modifying the lights? If not it seems like they'll stick out quite a bit.

I obviously can't say for sure, but it looks like the old one would have survived if it was just a few inches narrower. Might be something to keep in mind. This looks like an awesome homebuilt project.

badoosh27 · 05-11-2009, 12:05 AM

The lights are 4" wide, 1 3/4 deep and 1 3/4 tall. they should fit perfectly. here's some better pix of the fitment TOP/front:

Side:

it is gonna be tight, but it will work. also, as far as the old one is concerned, the whole windshield was bent in about 3-4 inches, so there's no way it could have survived, may it rest in peace

**SHAKEnBLAKE** · 05-11-2009, 09:31 AM

The link you gave shows measurements of 8 x 4.5 x 2.5 Are they just being generous with their measurements?

Before I had read your proposed cutting method I figured dremel would be the best way. I would cut a shape like a rectangle with the corners cut off, and then use a different attachement on the dremel to round the corners. I'm interested to see how you secure the lights.

Remember to take lots of pics and part numbers, that way I can copy... err, that way you can get it posted in the write-up section and get a year of JF for free!

badoosh27 · 05-11-2009, 10:31 PM

just saw the measurements on the link and i dont know what the heck they were measuring. The numbers a little higher up are the right ones: 5 x 1 3/4... I had to work all day today, but i did go by and pick up another pair of the lights so now i have all 6 ready to go. I used masking tape to mark off the parts i'm gonna chop out, so all i need to do is grind away. the ends of the light housings are not quite square, but i'm going to just chop the holes square instead of trying to match the radius.

As far as how i'm going to mount the lights, i was planning on using some sort of epoxy(very strong and weather proof) to sorta glue them in. There's no way to use the brackets they supplied and i dont want anything clamping across the lenses, so i think thats my best bet. whatcha think? I hope to cut the holes tomorrow, so i'll take pictures and post em when i'm done

xboxteen01 · 05-12-2009, 11:55 PM

this looks awesome, im interested to see how it looks when its all done. im in the process of deciding where to mount my 4 aux lights, either bumper or light bar and after this im leaning towards bar.

badoosh27 · 05-13-2009, 10:29 AM

I cut the holes out for the lights yesterday with an angle grinder b/c the dremel wheels were dissentegrating too fast and it was taking forever. The need some final trimming, but over all i'm happy. It's really hard to do this kinda stuff on my living room floor in my apartment, so if i had a garage i would be a lot happier. Also, i bent the brackets and rough fit them on the jeep to see where they could go. I'm going to have to mount the brackets to the jeep then mount the light bar from the bottom so that should be fun, the windshield is only partially in the way...

thanks for the compliments and i'll try to get some pics up today.

badoosh27 · 05-13-2009, 02:02 PM

here's some pics of the lights rough fitted in. i gotta pic up some epoxy and figure out the wiring before i can put them in for good. i think it looks cool, and is exactly what i was going for. what do yall think?

sorry about the blurriness, can't find the micro setting on my camera...

**SHAKEnBLAKE** · 05-13-2009, 06:57 PM

Looks good. What kind of epoxy? JB Weld? I assume the lenses come off for bulb replacement?
Pretty sweet...

badoosh27 · 05-13-2009, 10:26 PM

I was thinking something with the strength of JB, but clear or black... I just want to seal it up and hold them in place just enough. The lenses don't come off so if one burns out i want to be able to pull the whole thing out and replace the bulb from the back. I'm gonna try and work out the wiring tonight, so we'll see how that goes

GlennA · 05-14-2009, 07:50 PM

Have you cosidered using the double sided tape like is used for body side molding. Once it sets up, it is exceptionally strong. If you need to remove a light, some fishing line or dental floss behind the light will cut through the tape. JB weld sets up so hard, it would be almost impossible to remove the light without destroying it. Just my .02.

badoosh27 · 05-14-2009, 11:07 PM

yeah, thats what i was thinking about the JB "Weld". i think i'm gonna get some epoxy caulk and just run a bead behind the lights. they fit in pretty snug, just want it waterproof and a little more snug.

got the wiring done up last night, only to test it and have it not work, so i took it all apart tonight and am in the proccess of re-doing it. should be done and ready to epoxy then mount tomorrow. will post pics too

badoosh27 · 05-15-2009, 03:57 PM

Got the lights epoxied in using some clear silicon stuff from lowes, seems to hold them in pretty good even though its not fully cured. Also finished up the brackets, installed them, and spray painted them black, so i think i should be able to mount the bar after work tonight and get going on wiring them to the switches. i wired the lights to be on 2 switches (A and B) in the order | A B A A B A | so the A's are controlled by one and B's by the other. once i get it wired, i'll take pics so it will make more sense.

badoosh27 · 05-16-2009, 01:57 AM

Well, got the bar installed on the brackets, but not the way i want b/c the angle of the windshield makes it hard to drive them in fully. I'm gonna redo it with self tapping screws tomorrow maybe, but for now its secure and the lights work...somewhat. I need to get 2 new relays, one of which needs to handle 4 lights worth of power, need some advice on that one. I wired them in temporarily to the switch that controls the hood lights, so the "A" lights from the previous post can turn on. all of them work, just wired in those. Without further ado, here's the pics of it installed:

I will take some better pics tomorrow in the daylight, just wanted to give yall a sneak peek. Let me know what yall think...