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Old 02-17-2013, 12:07 PM   #1 (permalink)
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Default Lightbar completed!

I've been in the process of building this lightbar for a few weeks, and finally got it done. Just wanted to share some pictures from the build.
It was inspired by ForesterMatte (here: My homemade "bullbar"). My buddy Mike put this together for me, and he is starting a custom welding shop (I'll post the link here to their website soon).

It's made of steel roll bar tubing, and painted with plasti-dip. Very sturdy!

One of the mounting plates we fabricated:


The bottom part of the bar put together:

The cuts we did on the crossbars:

The bar getting close to done, just the top bar left:


And the completed bar, with lights!






I'm super happy with it! Looks great on the front of the car and should offer some good protection as well as a place to mount lights.
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Old 02-17-2013, 03:16 PM   #2 (permalink)
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Looks awesome! DIY FTW!!!
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Old 04-01-2013, 03:11 PM   #3 (permalink)
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Damn thats really good, Im very impressed
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Old 04-19-2013, 09:14 AM   #4 (permalink)
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Awesome job! How (& where) is it attached to the frame?
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Old 01-17-2014, 08:20 AM   #5 (permalink)
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It is attached to the car on the same mounts as the front tow points (the plate in the first picture was made to use the same bolts, and then it was welded to the light bar).

Unfortunately, this winter I hit a patch of black ice in a parking lot and smacked the lightbar up against a curb (luckily not another car!). I'm glad it was there though as without it I think it would have smashed the bumper up and could have broken the A/C and radiator mounts. Damage shown below:



It doesn't look too bad in the picture, but it's bent pretty far in, and the whole thing is tweaked enough that I couldn't get the hood open (it used to have about 1" gap for the hood release). It's also made of roll bar tubing, so bending it isn't easy.

Fortunately, I've got it mostly fixed again!
We ended up having to cut out the crushed section, and bend each end back to weld a new piece in the middle. Bending each end back was difficult, and we ended up finally being able to do it with some clever strapping in the back of a flatbed truck and a hi-lift jack. We had some leftover metal from making the light bar in the first place, which we were able to use to make a repair section. In the attached pictures you can see it cut and ready to weld.
After getting the new section welded back in, all it needs is to have the mounting plates re-welded so the bar isn't hitting the hood (They definitely shifted a bit in the impact) and a new coat of paint.

My plan after that is to bolt on a sheet of aluminum underneath it as a skid plate, so hopefully there will be more to come here soon!
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Lightbar completed!-9893d903-fb2f-400c-a42c-6262ec8c7e24.jpg   Lightbar completed!-18198b75-d9b1-43d6-867b-1749b9dad999.jpg  
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Old 01-17-2014, 09:31 AM   #6 (permalink)
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Dude, at first I was like...."Fack, someone just posted their light bar/mount build thread...I was gonna post mine next week :("

Then...I read yours and that is friggin AWESOME!!! Yours actually saved you from damage!! The Rally Innovations light bar is super chinzy and had you had that instead, you would have ruined your bumper, the light bar and possibly more!

I love to over build, under worry. Nice work!!!
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Old 04-18-2014, 09:04 PM   #7 (permalink)
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The only missing is an Amtrak horn. Cool looking bar.
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Old 07-04-2014, 02:13 PM   #8 (permalink)
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Looks so good, thinking of doing one similar for mine. How long did this one take you?
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