Homemade lightbar/rack writeup part 1 (picture happy)
Well in short I picked up a 180HD lincoln welder and wanted to fabricate something. I had plenty of 1/8" sheet metal and always wanted a light bar. I figured it would a good project to test out my new welder and beginner fabricating skills. First was the design, I was originally going to use the same method all the other lightbars and roof racks used and make a bracket that will go over the bottom left/right window bracket.
I found some cardboard and started tracing out the new design
After finding out that is would be a major pita to pound out the curves to match the original I decided to just make it a block shape and weld 2 halfs together.
After getting the cardboard to corporate the best I could I traced it out on the sheet metal and used a 4 1/2" cutting wheel to cut it out.
After this it came to me that I could just use this homemade bracket in place of the stock one instead of bolting it on top. I think this will make a cleaner look and because Im using all 6 bolts it wouldnt be a problem. After way too much grinding and test fitting I finally got it to fit atleast close enough so I can start welding. (Left side I can just flip these over and trace them out)
I tried tacking them together a few times freehand but decided to wait tell daylight so I can tape them onto the jeep and lay down a few tacks while they are in place. Because its such a odd shape I just couldnt get them to ever quite fit.
The pointy part will be the only spot I will need to take a hammer to and can easily do that after I start welding.
Next part coming tomarrow, should get it all welded up and will be trying out 1 1/4" electrical conduit for the bars. Because this is going to be part of a roof rack I wanted something strong with very little flex.
My new lincoln
Time for some
07 JK 2D X model with 6 speeds. Full Traction 3" ultimate lift kit. 315x75x16 Toyo Open Country M/T on Rock crawler procomp rim. Ruby dana44's front sleeved inside/outside C truss and rear with 5.13's gears. Homemade rock guards, rear bumper w/tire carrier, oilpan/tranny skid, evap canister skid, light bar, switch pod. Riddler diff covers, Cobra 75 w/wilson antenna, Polk speakers, 10" sub, 2x Amps, Lightforce 240 drive light, backup lights, rock lights.