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-   -   Congo Cage and Windshield Lights?? (http://www.wranglerforum.com/f282/congo-cage-and-windshield-lights-74984.html)

rgreenberg2000 01-07-2011 04:51 PM

Congo Cage and Windshield Lights??
 
I've been away from the forum for several months, sometimes life decides to reprioritize things for you!! :) Still loving my return to the Jeep life, and have done some minor upgrades to my stocker Sahara.

One of those upgrades was the recent installation of a Kargo Master Congo Cage rack. I did a ton of reading and the price/performance of this rack system matched up very well with my budget and what I'll need to do with the rack. I was a bit concerned about how the install would go after reading through some threads where people had trouble. I have to say, it went together quite easily (took my time, laid everything out before hand, etc.), and I'm very impressed with the fit and finish quality, as well as the sturdiness of the rack (which hasn't carried anything yet.....) ;)

So, I come to my plea for help from WF......I have a set of windshield mounted lights (Hella 500s), which no longer have a home with the install of the Congo Cage (which mounts in front to a support that looks VERY much like the one that my lights used to be attached to. I think that I could drop some sort of support behind the support plate mounting bolt that is in the face of the winshield hinge, but I don't have either skills or tools to fabricate something. I've hit the hardware store a couple of times looking for something I could use, and so far just hacked up a very lousy solution using some "mending strap" that I drilled and bent up (can't have the lights dangling from their wires up front!)

Does anyone have an idea of what I could use, or thoughts on common hardware store parts that would work? I need the mount to extend about 2.5" out from the hinge face so that the light will clear the rack's front legs.

Thanks in advance for any ideas!!!

Pics (please don't make fun of my jerry-rigged mount....it's ugly, and won't last as the lights bounce on them.)

http://lh4.ggpht.com/_iv65Q5DwLJ4/TS...0/DSC_0003.JPG

http://lh5.ggpht.com/_iv65Q5DwLJ4/TS...0/DSC_0002.JPG

Rich

oIIIIIIo 01-07-2011 11:23 PM

After I got my roof rack installed...I have noticed major wind drag and noise from it. Do you have this issue also?

rgreenberg2000 01-08-2011 04:00 PM

oIIIIIIo,

I read a bunch about wind drag and noise issues and saw two fixes that seemed to work for people: (a) wrap the front bar with rope (each wrap 3-4" apart) so that it breaks up the wind flow across the front bar, and (b) mount a fairing (Yakima, Thule, Tap Plastics, etc.) to the bar to direct wind flow above it. I guess the cause of the noise is harmonic resonance caused by wind flowing over the hollow tube (disclaimer: I'm a History major, so this is just me repeating what I read!!) :)

Anyway, since the rope option was cheaper, I started with that, and so far so good. I took the Jeep on the freeway for a bit up to 70 mph, and while there was a minor (very minor) increase in noise from the rack, it was really not very noticeable given the amount of noise the Jeep already makes (hardtop is currently on.)

I was planning to post a few pics of the racks installed, so you will see what I mean with the rope....

Hey, where are you in the Bay Area? I'm in Redwood City.

Rich

TXST8tj 01-10-2011 01:08 PM

would something like this design work?....where they bolt to the lower hinge instead of the upper.
perhaps if that exact mount won't work, the basic concept will.

http://www.quadratec.com/Assets/Imag.../115189-lg.jpg


It does seem like you would need to have the lights stick out farther from the hinge than those mounts would allow, but you could totally take that design and make your own version of it. All you would need is the steel, bench vise to make the bend, drill for the holes, and cutting tool to cut the steel into shape.

rgreenberg2000 01-10-2011 01:14 PM

Patrick-

I like the look of that, and it may solve my issue, though I suspect a custom fabrication will be needed since those don't look like the mounting shelf extends in front enough to clear the rack mount.....I see an opportunity to strip some more windshield hinge bolts!! :)

Thanks for the suggestion!

Rich

oIIIIIIo 01-10-2011 03:22 PM

Quote:

Originally Posted by rgreenberg2000 (Post 975063)
oIIIIIIo,

I read a bunch about wind drag and noise issues and saw two fixes that seemed to work for people: (a) wrap the front bar with rope (each wrap 3-4" apart) so that it breaks up the wind flow across the front bar, and (b) mount a fairing (Yakima, Thule, Tap Plastics, etc.) to the bar to direct wind flow above it. I guess the cause of the noise is harmonic resonance caused by wind flowing over the hollow tube (disclaimer: I'm a History major, so this is just me repeating what I read!!) :)

Anyway, since the rope option was cheaper, I started with that, and so far so good. I took the Jeep on the freeway for a bit up to 70 mph, and while there was a minor (very minor) increase in noise from the rack, it was really not very noticeable given the amount of noise the Jeep already makes (hardtop is currently on.)

I was planning to post a few pics of the racks installed, so you will see what I mean with the rope....

Hey, where are you in the Bay Area? I'm in Redwood City.

Rich

Cool, I am looking forward to your pictures. I need to have mine done.

I am in San Ramon, CA not too far from Redwood City.

rgreenberg2000 01-10-2011 05:04 PM

oIIIIIIIo,

I posted some pics in the thread "Congo Cage Installed" in the TJ forum. I just realized I didn't get a great shot of the rope, though, so I'll snap one for ya and either post it here or will PM it to you.

Yeah, I know San Ramon reasonably well, have a friend who's a member at Bridges golf club, and we have an office in Pleasanton....

R

oIIIIIIo 01-10-2011 05:15 PM

Sounds good Rich, thank you.

TroutBumTJ 12-12-2011 02:49 PM

So glad that I found this thread,as I too am considering the Congo cage and I just ordered a set of KC slimlites (100 watt driving lamps) that I wanted to mount on windshield mounts. Subscribed!!

TroutBumTJ 12-12-2011 03:58 PM

1 Attachment(s)
Ok so I found these

http://www.assuredautomotiveproducts...RD-VRT-CLP.htm

They are light clamps for vertical bars. Not sure what size the hole is for the mounting bolt but it gives you something to work from. You connect the lights to the front rack supports. you would need some quick disconnects for when you are changing/ adjusting tops.

TroutBumTJ 12-12-2011 04:42 PM

Quote:

Originally Posted by TXST8tj
would something like this design work?....where they bolt to the lower hinge instead of the upper.
perhaps if that exact mount won't work, the basic concept will.

It does seem like you would need to have the lights stick out farther from the hinge than those mounts would allow, but you could totally take that design and make your own version of it. All you would need is the steel, bench vise to make the bend, drill for the holes, and cutting tool to cut the steel into shape.

Maybe flip these upside down and mount to the opposite side they should be (passengers to drivers and vice versa). This would move the light medial to the front support bar and may give you enough clearance? The issue would then become clearance of the support bolt with the cowl panel.

TroutBumTJ 12-12-2011 05:09 PM

1 Attachment(s)
Possible winner!

Delta product # 01-6570-tjb

These look like they would mount to the two screws on the lower portion of the windshield hinge AND it moves the mounting point more medial. May give you the clearance you need for the lights. Pricey though! $54.


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