Homemade Lightbar

I worked all summer, and had nothing to do. So I decided to design a lightbar for the Jeep unlike any ever built before. Like most semi-trucks there is a triangulated visor over the windshield for blocking the sun, so I decided to incorporate this into my design because I like the look, and I also needed it to block the light thrown from the KC's. I also really liked the cages built around the baja buggies you see in desert racing, and since I am always barreling through densely wooded paths, the cage will help keep my lights upright and unaltered from tree branches and bears :).

I decided to use plumbing tubing (iron) from my local hardware store. Slightly more mailable than steel, and still easy to weld. The overall design is as follows 2 KC fog lights (mounted on the outside of the lighting array), and 3 KC long range lights (mounted on the inside of the array). At the end of the project I plan on getting the whole thing powder coated black and textured.

(Below: Iron tubing used for project)

 

Originally I was going to mount the lights upside down so I could tuck them over the windshield. However, after I got my KC's in I decided to deviate from this plan and mount the lights in the upright orientation. This is because of the air vents I discovered in the base of the lights, I did not want them to fill with water... Onto the first cut. Here is an image of the "V" section. The visor I mimicked from the semi-truck light visor. My goal was to droop one from each side and join them in the middle, providing a base for my cage.

In order to get the entire system connected to the Jeep I decided to use the bolts on the windshield frame (pretty much the only mounting location I could find). Simply by using longer stainless steel bolts and a custom mount made of angle iron and steel plate I had a solid mounting location for my light bar. Unfortunately, removing the existing bolts was more of a chore than I expected (paint + bolts = death). I first used the impact wrench and dremmel for a couple hours, that failed so I hit it with a propane torch and they came loose. This was a two person job, and a snag I was not intending. I did learn Jeep paint withstands a lot of heat, A LOT of direct blue flaming heat. Below is a picture of the torx bolt I stripped, and cut with the dremmel to twist out.

 

With the base of the system built I moved onto the cage. I left the base attached through the entire tacking process -which made it much easier to construct. The base of the lightbar ended up acting as windshield armor as well. I know this because I have deflected many tree limbs with it. Below is the base of the light frame. Five light tabs, and the triangulated link.

Below is a picture of the cage construction. One bar runs along the top, and four bent pieces connect it to the triangulated link.

(Below) Fully welded and grinded. Ready for the powder coaters. Next step, wiring... :(

Now onto wiring... I decided to go with two separate circuits. One for the fogs, and one for the long range lights. Trust me when I say, the thicker the wire, the better! These suckers draw a ton of current, and I had to re-wire 2 times to get it right. Don't end up like me, do it right the first time, or else you will end up with melted smoking wires. I ran the power through the firewall and under the dash by the passengers feet, since that was the shortest length to the battery and a dry location. That is where I installed the relays and my really cool rocker switches. I then ran the hot wires up the inside of the windshield housing to the top where I drilled a hole (of which was plugged with a rubber grommet to prevent rusting). I attached a ground wire right by the hole too (the shorter the wire the better). Then I just simply wired up the lights.

Those suckers throw some light!