Light bar with guard

[galacticfuzz]

Agreed Chris, looks are good, functionality are key. As for mounting the lights on the horizontal bar and tubing. The mounting bolt which hooks into the light is too short to mount to the bar with the adjustment blocks that sit behind the light and lock it in place. I had looked at doing that first with the bar I have and decided to upgrade in a way.

[janesy86]

Awesome! Looking forward to seeing it mounted!

[navigator]

Agreed Chris, looks are good, functionality are key. As for mounting the lights on the horizontal bar and tubing. The mounting bolt which hooks into the light is too short to mount to the bar with the adjustment blocks that sit behind the light and lock it in place. I had looked at doing that first with the bar I have and decided to upgrade in a way.

I figured there was a reason. I'll have to keep that in mind when looking at lights.
I bought an 8ft stalk of 1inch alum tubing a while back. I was in a bind and used 4ft for side rails for my roof rack.
I plan to use the remaining 4ft on a light bar.

[galacticfuzz]

and painted. Now onto the wiring.

Obligatory crappy cell phone pic.

[Trail X]

It will be interesting to see how the vibrations are. Not exactly what I envisioned when I suggested adding support to the tabs, but it will help some. If you still get vibrations, you may need to gusset the tabs back to the main support bar. Try it as is, and if you notice issues, we can certainly help you out.

Looking forward to seeing it all mounted and wired up.

[galacticfuzz]

Thanks James,

It seems pretty solid right now on the tabs, so that's why I'm going to go ahead and test it out the way it is. I definately see where that may be an issue though. The other concern that I have is the mounting set up. Currently it's only one bolt on either side, but with the weight of it I may have to add an additional piece in front or behind to help the stress at the mountings.

[OregTrailBlazin]

. The other concern that I have is the mounting set up. Currently it's only one bolt on either side, but with the weight of it I may have to add an additional piece in front or behind to help the stress at the mountings.

That was what I was trying to get at in my original post, I don't think it came out right .

I would definitely put something to add another bolt location further back. That way if you do hit a branch or something hard enough to need the guard it won't rotate backwards on your mount and end up putting your light tabs into the roof.

[galacticfuzz]

Ah... No worries. I probably misunderstood what you had commented on. I have some scrap angled steel that I may weld on the back of it, which would allow me to have another mounting part. May do front as well, we'll see what is all needed.

[Regulator1175]

Extend the stabilizer bar that you have on the mounting tabs all the way out to the side. This will provide another mounting point as well as help in stabilizing the lights themselves and preventing vibration.

[navigator]

Extend the stabilizer bar that you have on the mounting tabs all the way out to the side. This will provide another mounting point as well as help in stabilizing the lights themselves and preventing vibration.

I would think that would make it rock solid!

[OregTrailBlazin]

Extend the stabilizer bar that you have on the mounting tabs all the way out to the side. This will provide another mounting point as well as help in stabilizing the lights themselves and preventing vibration.

I would think that would make it rock solid!

[bartonmd]

Extend the stabilizer bar that you have on the mounting tabs all the way out to the side. This will provide another mounting point as well as help in stabilizing the lights themselves and preventing vibration.

I would think that would make it rock solid!

Winner! My thoughts, exactly!

Mike

[galacticfuzz]

will have pics of it tomorrow as well as it mounted. Don't have a chance to do so tonight, plus it's all rainy and stuff here. Gonna also add a 2 flat connector to make it easier to remove for not using it time.

[galacticfuzz]

Well, things didn't go exactly as planned. Apparently when I did the welding, the tubing warped slightly, causing the mounting holes to be off about 1/8th of an inch on the inside, to where I can't get the mounting bolts even into the tracks. The wiring is all enclosed through the tubing. I checked to make sure that they all lit when hooked in and that at least went according to plan. Sadly, I can't get back into my lab until Monday at my school since they have it closed up (key cards won't work till 6am Monday morning ). So for now they ride in the back of the Trailblazer.

[SomeOffPave]

Well, things didn't go exactly as planned.
You never heard of Murphy's Law before this project?
Apparently when I did the welding, the tubing warped slightly, causing the mounting holes to be off about 1/8th of an inch on the inside, to where I can't get the mounting bolts even into the tracks .

Oversize holes and fender washers will take care of that. I have been there hundreds of times. Not proud of it, but been there.

[navigator]

looks tight and like it will be solid.
We're all waiting patiently for you to light up the night sky!

[chrisN]

That looks really good and solid like navigator said. Excited to see it mounted and lit up.

[galacticfuzz]

Well....I got it up and mounted. Here are the pics. I'm a little irked that I didn't think about the overall height. It seems that by solving one problem (smacking lights) and upgrading a little, I've added a good bit of height. I'm a bit undecided at the moment. Never mind one of the welds broke...coincidentally one of the first welds on the bar.

[DirtyBacon04]

Looks great man! I'll take one!

[Mudwheelin]

Ill take one to! That looks awesome! Im thinking you should sell these things. Id buy one.