Deuce Light Rack Build

[General Mcgregor]

Here's a project I've been wanting to do for a while, I have always wanted additional lighting on the truck and loved the idea of a light bar on the roof. I want something that looks military and will hold up to moderate and occasional off roading.

I drew up a concept of the bar, I'll be building it out of 1'4" x 1" flat stock and a section of angle iron. I am designing it to accommodate 6 rectangular off road lights.

Before anyone says anything I really do prefer the look (and cost) of traditional halogen lights despite the energy, brightness and size advantages of LEDs. Maybe on a more modern truck I would get LEDs but this is the best way to get the look I'm after.

The rack will mount to the outside of the windshield frame and will work for either a hardtop or a soft top. It will also be able to articulate forward to allow for hardtop removal or backwards so the lights can still be used even with the windshield folded down on the hood. It will also not interfere with my M66 when installed.

Here is my concept, already have most of the material build updates will follow soon.

 

[m109a2]

Oh, I will need a pic or three of this build.This has been bouncing around the grey matter for a long time.

 

[General Mcgregor]

Weekend project is going good so far, got most of the parts cut and the main bar drilled.

 

[tomcata3]

I was thinking about doing the same thing, I will wait to see yours
Thanks

 

[General Mcgregor]

Long day in the shop but she's all welded up! Done for today, more to come tomorrow stay tuned

 

[General Mcgregor]

Today I got the mounting brackets built, punched out the holes and welded some mounts on the sides for a future project.

 

[General Mcgregor]

Anyone have any suggestions for mounting hardware to the windshield frame?
I know the metal in there is really thin and want to make sure it can withstand a potential beating on the trail. I was thinking about using large self tapping screws.

 

[jbayer]

I would do something similar to what Valence did:
http://www.steelsoldiers.com/showthread.php?125231-My-HMMWV-Lightbar-Install

 

[General Mcgregor]

Ideally I think that might be the way to go, but my brackets align with the rear of the windshield frame as opposed the the front.
The whole bar might end up at an angle that way but I'll look into it.

Thanks!

 

[Hainebd]

Nutzerts. I installed a light bar on my cj with 6 kc day lighters on and never had an issue. Nice work on th light bar. Are you powder coating or rattle can?

 

[General Mcgregor]

Nutzerts. I installed a light bar on my cj with 6 kc day lighters on and never had an issue. Nice work on th light bar. Are you powder coating or rattle can?

I'll be powder coating it but it's getting painted again with the truck in the spring.

 

[peashooter]

Anyone have any suggestions for mounting hardware to the windshield frame?
I know the metal in there is really thin and want to make sure it can withstand a potential beating on the trail. I was thinking about using large self tapping screws.

I ended up using Rivet nuts to mount my lightbar on. Here is more info on my setup and installation in case it helps at all: http://www.steelsoldiers.com/showth...Build-Thread&p=1376669&viewfull=1#post1376669

 

[turnkey]

Nice setup with the remote control.....side lights are handy also...ended putting LEDs on side of my M35A2.

 

[General Mcgregor]

I ended up using Rivet nuts to mount my lightbar on.

I think I will be going the Rivnut route if I can borrow or find a kit for a reasonable price.

 

[peashooter]

I think I will be going the Rivnut route if I can borrow or find a kit for a reasonable price.

I've used a couple kits. The first one I bought at a Menards store (Sort of like a Home Depot). That Rivet nut kit had a variety pack of different size rivets along with the tools, and was about $20. It came in so handy and I liked it so much that I decided to get a nicer kit that would last me longer.
Here is one of the cheaper versions from Amazon: http://www.amazon.com/Surebonder-85..._indust_6?ie=UTF8&refRID=0AGH2DZF2RK3E5BWAH7D

 

[General Mcgregor]

I think I'll probably grab that one from Amazon.

 

[Hainebd]

You do not need a special tool to install. Just use a bolt and nut with two wrenches. Hold the nut and tighten the bolt. Hole size is very important. Use a new bit. Better yet drill hole undersized and use the proper reamer. Keep the picks coming.

 

[Danger Ranger]

Interesting. Yours looks real good Peashooter.

 

[Lieutenant Dan]

48" federal signal vision smart bar with a 42" led bar.

 

[DeucesWild11]

Love that snorkel Lieutenant Dan, even if you can't breath the truck still can.. ha ha.