2x4x 1/8 rectangle and the side pieces are 3/16 plate, could use 1/8, I only had the 3/16. I built the bar first, figure out how long , I think I was shootin for 55"! I cut two notch's in the 2x4 and pulled it back together and welded it. This was so its not just a boreing straight bar! I bought a light kit for a Tough stuff hood light bar. And I bought the LED's locally. Lay all the lights out and measure two or three times!!! I used a few different size hole saws in my drill press, and a 4" cut off wheel to connect the dots. Dremal to clean it all up and flapper disc. wired it according to the light kit. LEDs tied into the running light switch!
Great looking Light Bar! Can I ask how you attached it to the windshield? (What did you use for nuts in the pillar)
Also how did you run your wires into the cab? Thanks
1987 YJ, 258, Weber 32/36, HEI, Custom Sound bar, Hardtop/Sun-rider/bikini tops, 2" Lift, 1/2" Boomerangs, 1" Body & MM Lift. 32x11.5x15 Copper STT's on Black Rock 950 Lobos w/4" backspacing, Still need Front Bumper and Seats.
My build thread: [url]http://www.jeepforum.com/forum/f12/my-very-slow-87-yj-build-thread-1137667/[/url]
It looks great, but i think it has to many unneeded mounting locations. 6 screw/bolts on each side little much my opinion but none the least still looks sweet. Like the low pro design and the actual rail to hold it in place nice not being just straight up to the light bar. Looks great.
Sorry, My wife was rushing Me out the door, so I could'nt finish the last post! I used a piece of cardboard to mock up the side parts. As in the pictures, I laid a couple 4' levels across the top of the hard top and clamped the light bar to it. I put a heavy piece of angle on the levels to hold them down. Had to get creative! I moved the bar around till I liked it. (angled down just a touch). Bending the side plates was a pain. Used My vise and some heat. The side pillers on the windshield are actually quite beefy, 3/16-1/4" I drilled and tapped the holes. 12 countersunk hex head (same as windshield and door hinges) were used so the boltheads wouldn't snag branch's.
I then drilled a hole in the driverside upper corner of the windshield frame to pass the wires down through the inside, and out where the wiper wires go into the dash. I put alot of thought into this, and am pretty proud of how it came out! I would have never guessed that someone would say I have to many mounting points! To each his own! Where We wheel around here, it's usually pretty tight through the woods. Not uncommon to take a big branch in the windshield and plow through it!
[FONT="Comic Sans MS"]"Working with cars is a little like a really awesome date: you start out expecting this to be simple and straightforward; four hours later you're laying under her, panting and cursing, and things are a lot more complicated than you thought."[/FONT]
[B][FONT="Tahoma"][SIZE="3"]I [U]drove[/U] [/SIZE][SIZE="4"][COLOR="White"]okee[/COLOR][/SIZE][/FONT][/B] ('92 XJ)
then I wrecked him...
[B][FONT="Tahoma"][SIZE="3"]I [U]drove[/U] [/SIZE][SIZE="4"][COLOR="Red"]r[/COLOR]okee[/SIZE][/FONT][/B] ('93 XJ)
then I rolled him...
[B][FONT="Tahoma"][SIZE="3"]I drive [/SIZE][SIZE="4"][COLOR="Red"] Clifford[/COLOR][/SIZE][/FONT][/B] ('79 J-20)
I'm guessing the multiple cutouts on the 2x were to decrease some weight and give it some design aspects? Did you box in behind the lights themselves or are they open to the elements? Great job, by the way! I have a standard "tube" type light bar that I have gone back and forth on a million times on getting rid of it or not. I like the low profile boxed style much better, but like you, refuse to pay for the outrageous Delta bar.
Did you wire the lights to be all on/all off, or for multiple combinations like the Delta bar? i.e. 2 on, 4, on, 6 on..... Thanks for sharing your ideas!