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  #1  
Old 04-19-2011, 09:46 AM
SpitfireEMT SpitfireEMT is offline
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Default My first fab: Front light bar

Just a few pics, more of a personal photo log than anything.
2x2" angle iron
33 1/2" overall length, 8" in between mount center holes, allowing for 1.5" space between each light, in this case Hella 500FFs, with 3/8" holes. With approx 4.75" left on the outside to allow for mounting of larger lights or accessories as I see fit later down the road.
The mounts are cut from the same piece of stock, measuring approx 2" across, with 3/8" mount holes for securing to my bumper using existing holes from my current lights.
It was cleaned with a wire wheel and then cut with a plasma cutter, then a lot of grinding and smoothing of rough edges.
I used shielded metal arc welding, or stick welding, to attach the brackets.
The beads are a little nasty still, and I plan on cleaning them up and perhaps doing some preliminary mounting this evening as time permits.
Anyway, here it is, in mostly chronological order:
Raw stock, 2x2" angle iron, painted with some kind of nasty junk. Measurements are rough and exact measurements were done and scored prior to cutting.

Post cut & rough polish. Before I mounted the brackets.

Bottom of bar, mostly finished construction, still needs cleanup on beads and a final good polish and shaping before permanent mount on my truck

Front view. DS mount is a little off, will likely heat and bend to make even.

Top view, showing mounting surface for lights as well as showing the top side of the brackets. The brackets stick out approx 1/4" behind the bar itself, due to plate thickness, will be negligible upon mounting.


Ill clean it up a bit more and paint it and then post some pics installed when it occurs.
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2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #2  
Old 04-19-2011, 10:25 AM
FoMoCo FoMoCo is offline
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Default Re: My first fab: Front light bar

looks good, can't wait to see it done
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  #3  
Old 04-19-2011, 10:30 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar

Thanks. I will clean it up tonight and probably put a layer of paint on it, but it wont be finished til after the first of the month. Gotta get another pair of lights for the center.
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2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #4  
Old 04-19-2011, 11:02 AM
Christianguy Christianguy is offline
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Default Re: My first fab: Front light bar

Nice job!
Be sure to update PICs after your install
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1999 Ford Ranger XL
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  #5  
Old 04-19-2011, 07:47 PM
tpl593 tpl593 is offline
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Default Re: My first fab: Front light bar

looks good man...im doing the something similar except i ordered my L brackets online im jsut gonna weld a piece of metal between them....do u know what lights you are gonna put on the bar?
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2005 FX LEVEL II Blue Led's in grill dash & back window, Tinted tails and clear corners, 3 inch PA Lift, 33x12.5 Duratracs, Front Light Bar with 2 KC 55 Watt Fog Lights and 2 55 Watt Driving Lights
Mods to come: black powdercoated rims, painted valence and fender flares
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  #6  
Old 04-20-2011, 07:17 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar

I already have a pair of Hella 500FF on the bumper, so I will be putting those on the outside, and will likely put a pair of Hella 700FF on the inside, if I can find a pair reasonably priced.

Thanks for all the positive comments guys, really boosts my confidence in making this kind of stuff. Maybe I will throw together a bumper or something next, Im getting tired of my chrome XLT bumper.
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2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #7  
Old 04-20-2011, 10:21 AM
VegasRanger02 VegasRanger02 is offline
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Default Re: My first fab: Front light bar

Paint the chrome. Im going to paint my chrome white. Just sand it real good and prime it up with some self etching primer.
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2002 Ranger XLT 3.0
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  #8  
Old 04-21-2011, 03:33 AM
Marine513 Marine513 is offline
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Default Re: My first fab: Front light bar

Does that chrome paint actually look nice? I have never used it , my trucks all blacked out not really any chrome so
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  #9  
Old 04-21-2011, 08:59 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar

I would be painting over the chrome on my rear bumper. I personally am not a fan of chrome. I redid my entire front end and went from the xlt bright package to the EDGE chromeless edition. Finding a decent edge bumper in my color is hard, seeing as they didnt make it. Im likely just gonna grind the crap out of it and have it powdercoated black and call it done, that or fab a square tube bumper.
I have painted pics of the bar, will upload after my break.

----------



__________________
2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #10  
Old 05-13-2011, 06:35 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar

Got a couple mock up picks with lights. Gotta redrill the holes. Drilled em out to 3/8", needs to be closer to 1/2"


And with a familiar object for size reference:


----------

Sorry for the blurry first pic, my phone does not light reflective surfaces apparently.
__________________
2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #11  
Old 05-20-2011, 08:00 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar





__________________
2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #12  
Old 05-20-2011, 09:01 AM
Justincredible Justincredible is offline
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Default Re: My first fab: Front light bar

sick! very clean and not over done, i like it a lot
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  #13  
Old 05-20-2011, 09:40 AM
Clinton Clinton is offline
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Default Re: My first fab: Front light bar

Not bad man!
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  #14  
Old 05-20-2011, 09:47 AM
SpitfireEMT SpitfireEMT is offline
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Default Re: My first fab: Front light bar

More importantly total cost: $130 for the lights. the bar and paint were free. $2 for a half gallon of diesel for the generator on the welder I used. Still, not bad, all things considered.
__________________
2000 XLT 4x4, 4dr ext cab, 4.0L OHV, 4.10 LSD
265/75/16 Goodyear Duratracs
Mountaineer seats, Expo OHC
2003 EDGE front clip conversion
133rwhp/192rwtq-->6-28-11

1969 Mercury Cougar
351W, FMX, 3:1 open diff in a Ford 9"
Undergoing restoration
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  #15  
Old 05-20-2011, 10:11 AM
Clinton Clinton is offline
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Default Re: My first fab: Front light bar

Quote:
Originally Posted by SpitfireEMT View Post
More importantly total cost: $130 for the lights. the bar and paint were free. $2 for a half gallon of diesel for the generator on the welder I used. Still, not bad, all things considered.
Yeah that isnt bad at all. What about painting the bar to match the bumper?
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