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Old 02-27-2012, 05:46 PM   #1
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Custom made Light bar

I decided to make myself a Light bar/Windshield guard today after breaking my windshield on a branch while trailing the other day. I went to my local metal/ weld shop and picked up..
2 6ft 1 1/2 inch tubing
1 6ft 1 inch tube
3x3 Sheet metal



Some angle iron So my windshield frame doesn't get smashed in


Fitted up Some mounts





So the lights are not going on to of the bar. Im actually fitting them unerneith that bar across the window. I haven't made the lower bar yet because i don't have the lights and want it to e perfect.





I haven't welded on the mounts for the lights yet im waiting to get the lights in the mail first. I ordered 5 Rugged Ridge ultra slim 6" 130W with stone guards.

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Old 02-27-2012, 06:06 PM   #2
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limb risers.. was a new one on me.

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Old 02-27-2012, 06:59 PM   #3
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I did the same
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Old 02-27-2012, 07:00 PM   #4
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Or close to the same
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Old 02-27-2012, 08:48 PM   #5
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Nice. I love having a Welder!
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Old 02-28-2012, 06:23 PM   #6
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I did not weld any on mine, wish I had a welder. Yours look good
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Old 02-28-2012, 06:40 PM   #7
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I fold me windershield down when wheeling after hitting tree with ot pn jump seat side! Had to take an 8' 4x4 in back of both door openings and use a porta ppwer to puch front of tub forward enpugh to close door! It cracked glass on pass. Side and whats sucks is I had just replaced it aboit 2 months earlier! That was 2 years ago and yes, the cracked glass is still on jeep lol
If its raining it stays up, but I dont hit the tougher trails in rain so less chance to do damage, its me daily driver after all
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Old 02-28-2012, 09:59 PM   #8
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Old 02-28-2012, 11:38 PM   #9
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Welded on The Top brush guard. It feels to tall to me.. I think I may cut it down tomorrow but it might just seam weird with ought the lights. Made the light brackets today. Not sure were i want them located on the bar yet. I'll burn them in when I get the lights. They were sent out today







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Old 03-01-2012, 05:12 PM   #10
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I didnt like the looks of the light bar. So I cut the mounts and lowered it 3 inches. Looks better now.. Also Sandblaster and Etched the whole thing to get it ready for paint. I get the lights in tomorrow so I'll weld the mounts on were the lights need them at.

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Old 03-01-2012, 05:47 PM   #11
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Awesome
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Old 03-01-2012, 07:04 PM   #12
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I'll have pics with they lights on tomorrow night. Will paint it Saturday.. Thats my plan anyways.
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Old 03-05-2012, 10:53 PM   #13
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Finnally Got my lights! the weather delayed UPS so i got them today instead of Friday. I'll be making the mounts tomorrow and hopefully get to see them mounted up.



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Old 03-06-2012, 05:02 PM   #14
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Worked at the shop today.. I was determined to get everything all finished up! Heres the finished product. May take it down and throw some red in there somewhere.



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Old 03-06-2012, 06:07 PM   #15
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SAWEEEETTT!!!! Looks awesomes man, great job.
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Old 03-06-2012, 06:13 PM   #16
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Thanks! Spent about 100$ in metal and thats about it! I cut and redid like 7 times cuz i didn't like certain things. It wouldn't take nearly as much work next time
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Old 03-06-2012, 07:37 PM   #17
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I really like that... Came out stellar!
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Old 03-06-2012, 08:38 PM   #18
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Old 03-06-2012, 08:39 PM   #19
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$100....Cheap enough and its a 1 off custom, cant go wrong there. Now if you only lived here in Arkansas, I could put a mean powder coat finish on that thing.
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Old 03-06-2012, 10:14 PM   #20
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Yea i'm wanting to get it powder coated! My buddy has the whole kit he does car wheels and smaller things localy.. But his oven isnt big enuf If i had my own pipe bender Id love to Make and sell a few things! but running back and forth the the local metal working shop gets old quick!
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Old 03-06-2012, 10:38 PM   #21
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Build one for me??

I've been looking for a light bar that holds 4 lights, but I'd rather not pay the $160+ companies are charging for them. Plus I need one that can hold HID ballasts somewhere, as I intend to fit HID lights to the lights.
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Old 03-06-2012, 10:51 PM   #22
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I have a white yj with black and red accents. Nice to see I'm not the only one. that top bar would look nice in red...
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Old 03-07-2012, 02:05 AM   #23
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dont you have accses to a welder xpress?? And Siffo I originally had the light bar painted red.. It almost seamed like.. To much red. So i sandblasted and painted black. But i May redo it and paint certain parts red.
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Old 03-07-2012, 04:44 AM   #24
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WOW great build!

Could ya do me a favor and tell me what sizes you cut everything? (ignoring the light brackets)

It looks really great and I wouldnt mind building something like this for myself!

thanks!
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Old 03-07-2012, 06:05 AM   #25
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What size angle iron did you use and how did you secure it?
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Old 03-07-2012, 06:31 AM   #26
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Looks great! I like to light protector. I swear that when I see jeeps with light on the top that they have ripped off more than one.
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Old 03-07-2012, 07:54 AM   #27
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Yeah I took a chance a couple months after I graduated high school and opened up my own powder coat shop. I bought a brand new spray booth, powder coat oven, powder coat machine/gun set up and everything. my #1 oven is 8ft wide 8ft tall and 20ft long my #2 oven is 3ft by 3ft by 3ft. That was 10 yrs ago this yr and still going strong. course at the time I was only the 2nd one in Arkansas doing it to the public im still the only one within a 100 mile radius.
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Old 03-07-2012, 09:15 AM   #28
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I'll make a Diagram today of all the sizes if ya want that. The angle iron is 1 inch and i secured it by drilling two holes threw the windsheild frame on each side i'll take pics in a sec. Your powder coating shop sounds Awesome! good for you! 8x8 is huge!
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Old 03-07-2012, 09:52 AM   #29
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Ok heres the diagrams





Heres what that bolts look like on the inside of the frame



This is what i messed up on first time.. I didnt think about the Frame being narrower at the top! So what i did was cut the angle iron first.. Drill the whole bolt it on.. And tack it all up on the jeep then take it down and finish weld evrything else.

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Old 03-07-2012, 09:53 AM   #30
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IT's 78 degrees out! im going to go wash my girl

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