I am planning on building my own rack system for the front of my 2001 TJ to support my 50" Federal Signal Vista light bar. The bar itself weights roughly 60lbs.
Here's where I stand with this project right now. I currently have the bar mounted directly through my hard top this winter, but come the summertime I wan't to be able to remove the roof without having to take the bar off. So I did some searching and found this video which shoes a Whelen Ultra Freedom light bar mounted to a still unidentified windshield rack.
Carr makes one similar but I don't think its the same one let alone one that could support 60lbs at highway speeds.
So here is the design that I have been working on for a home made rack system. If anyone here is familiar with the program Google Sketchup the original project file is located in the Dropbox folder for download.
Yes, I am aware that the main beams are not in line with the windshield frame. They will be during the actual build. This is just a rough draft of what I have planned right now.
This is the material I am planning on using
The entire assembly will be bolted together, not welded. I do not own a welder capable of making the kind of welds necessary for this kind of build and I would rather much be able to dissemble the entire thing if I ever need to.
I am looking for as much input as possible. If anyone has any suggestions please post them! Also if anyone knows of a already pre-made front rack system that could support 60lbs at highway speeds safely please post it below. It would save me a ton of time. However I don't wan't a full rack system with the cage over the roof. I just wan't the front racks. I don't have the money to spend on the full system.