jurick
Active Member
- Joined
- November 30, 2007
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- City, State
- Maryland
- Year, Model & Trim Level
- 97 Eddie Bauer
Well after being inspired by other posts on this forum I decided to make a light bar. You may need to look at the pictures below first to understand some of the things I am talking about.
I started off with a piece of 1"x1" steel square tubing. I believe that I cut it down to about 42". The bolts on the lights that I bought were not long enough to go all the way though the steel tube so I welded on 4 brackets for the lights to attach. Then drilled the holes and mounted up the lights(I got them lights from Harbor Freight for $15). I then got 1" plugs for each end of the tubing off of the internet.
I wanted to make this thing also look very clean and professional so I decided to run all the wires inside of the tubing. I drilled holes and used rubber grommets in the holes then sealed them with silicone. If you notice from the pictures below the only wire going into the tube is the hot the ground is screwed onto the tube at each light and the tube acts as a ground. Then at the end there is a main ground screw that has a 12 gauge wire running off of it to a ground on the body.
Now for how I mounted it up. I didn't want to use any of the anchors that were already there so I made my own. I took some measurements and ended up using a piece of 3/16" thick by 1" wide flat steel. I did have to shave a little off of the ends because it is a little less than 1". I then used a 3/8" grade 8 bolt to secure it. I tightened down the bolt first and then tightened up the nut to the bottom of the steel and it prevents it from coming loose.
Now for the electrical. Them lights are 55 watt lights so in total I have 220watts worth of power for them lights. I decided to run 12 gauge wire, use a 30amp relay and then a 20amp inline fuse. The wire comes from the light runs into the weather stripping for the door then into the fender out to the relay. I then decided to mount the switch in the glove box for them so I just ran a wire over there.
Full view
Full view with lights on
Back side of light bar
Back of light
Relay mounted
Switches, order- 2wd/AWD(brown wire mod), light bar lights, and power antenna.
I started off with a piece of 1"x1" steel square tubing. I believe that I cut it down to about 42". The bolts on the lights that I bought were not long enough to go all the way though the steel tube so I welded on 4 brackets for the lights to attach. Then drilled the holes and mounted up the lights(I got them lights from Harbor Freight for $15). I then got 1" plugs for each end of the tubing off of the internet.
I wanted to make this thing also look very clean and professional so I decided to run all the wires inside of the tubing. I drilled holes and used rubber grommets in the holes then sealed them with silicone. If you notice from the pictures below the only wire going into the tube is the hot the ground is screwed onto the tube at each light and the tube acts as a ground. Then at the end there is a main ground screw that has a 12 gauge wire running off of it to a ground on the body.
Now for how I mounted it up. I didn't want to use any of the anchors that were already there so I made my own. I took some measurements and ended up using a piece of 3/16" thick by 1" wide flat steel. I did have to shave a little off of the ends because it is a little less than 1". I then used a 3/8" grade 8 bolt to secure it. I tightened down the bolt first and then tightened up the nut to the bottom of the steel and it prevents it from coming loose.
Now for the electrical. Them lights are 55 watt lights so in total I have 220watts worth of power for them lights. I decided to run 12 gauge wire, use a 30amp relay and then a 20amp inline fuse. The wire comes from the light runs into the weather stripping for the door then into the fender out to the relay. I then decided to mount the switch in the glove box for them so I just ran a wire over there.
Full view
Full view with lights on
Back side of light bar
Back of light
Relay mounted
Switches, order- 2wd/AWD(brown wire mod), light bar lights, and power antenna.
I hope you made the rack removable... I didn't, now I have to have it done. One suggestion, have the wiring tucked away or away from the elements and wind. I'm finding damage to one of my cables from the wind... and rust on the bolts.
