Roof Bar Spot-Lights

Simon72 · Mar 19, 2008

Right I am thinking of having a roof bar made, I don't really want to pay for one of the over priced ones with the all singing and dancing plastic coating.

I work for a large company that have Laser cutters and a nice wet dip and powder coat paint plant ;-)

Right my questions are:-

1. Could some one take a picture for me of there gutter mounts so I can see how they are constructed, and mounted.

2. Then could they do a quick measurement of how high they sit and the sort of angle they pretrude forwards of the gutter.

3. Then the approx measurement of the spacing between the light mounts. (Four Lamp Arrangement)

4. The next big question is how did you get the wiring from the bar into the cab so I can power the spots.

Many thanks.

If it works out correctly, I might knock up a few of them and then sell them off on here or e-gay ;-)

RAZ8550TDI · Mar 19, 2008

dont be a cheap skate and just buy one fer 45 quid! mounting brackets are just an L shape, the bar has to be bent around the shape of the screen, the bar sits about 2 inch forward from the bracket and about 4 inch high.

RAZ8550TDI · Mar 19, 2008

ooo and mount yer light underneath as they will be less prone to being clouted by trees!

Simon72 · Mar 20, 2008

RAZ8550TDI said:
dont be a cheap skate and just buy one fer 45 quid! mounting brackets are just an L shape, the bar has to be bent around the shape of the screen, the bar sits about 2 inch forward from the bracket and about 4 inch high.

RAZ8550TDI said:
ooo and mount yer light underneath as they will be less prone to being clouted by trees!

Cheers, Look after the pennies and I will be able to put more chip fat in the tank, lol.

Helps when you work for the BIG YELLOW DIGGER COMPANY (You Know The One) and I can get almost anything knocked up and Laser cut and shaped, then painted ;-)

I was going to mount underneath anyway because I think they look a little GAY above

metallicachick86 · Mar 20, 2008

How do simon, yeh i'll give yah a lift (lucky get) i'll take pics either tonight or saturday and email them you if you PM your address. Will do some measurments too.

There fixed to the gutter mount using captive nuts with the bolts coming underneath (will get a decent pic)

In the case of wiring, the Haynes 'guide to modifying disco's' book, they drilled holes all along the back and kinda pulled all the wires through using hooks........ yeh right!!!!

So we've just fed them all along the back of the bar, used very precise measurements of wire for each lamp (well pair, one goes off the other) and secured it all with small black cable ties. you can't see it unless your stood behind or slighty to the side. Was gonna get some cable armour, but thats another days job

You should see my engine bay, its a mass of wire and only Tom knows where it all goes!

RAZ8550TDI · Mar 20, 2008

no, thats how yer light bar should come with holes through the bar!!

RAZ8550TDI · Mar 20, 2008

yer got a tube bender aswell??

Simon72 · Mar 20, 2008

metallicachick86 said:
How do simon, yeh i'll give yah a lift (lucky get) i'll take pics either tonight or saturday and email them you if you PM your address. Will do some measurments too.

There fixed to the gutter mount using captive nuts with the bolts coming underneath (will get a decent pic)

In the case of wiring, the Haynes 'guide to modifying disco's' book, they drilled holes all along the back and kinda pulled all the wires through using hooks........ yeh right!!!!

So we've just fed them all along the back of the bar, used very precise measurements of wire for each lamp (well pair, one goes off the other) and secured it all with small black cable ties. you can't see it unless your stood behind or slighty to the side. Was gonna get some cable armour, but thats another days job

You should see my engine bay, its a mass of wire and only Tom knows where it all goes!

Cheers for that, I will PM you my E-mail Address.
How did you get the supply from the engine bay to the light bar?
Was it via the bulk head into the car and then through a hole in the roof somewhere?

RAZ8550TDI said:
yer got a tube bender aswell??

Yes we have tube and breakpresses here at work also nice precision Trumph Lasers.
Once I have all the dimensions and angles I will have them CAD drawn and down loaded to the benders and Lasers. Then weld them up and send them off on a journey around the paint plant, any colour as long as it is Black or Yellow ;-)

Simon72 · Mar 28, 2008

Thought I would do a progress of the making of the roof bars.

So far I have had the brackets Lasered and bent.

Next I will be having the cross bar cut and bent and the lamp brackets welded.

Here are a few pictures so far.

Pikey · Mar 28, 2008

They look good If you've got the templates on a cad package can you email them to me as I wouldn't mind knocking one up for myself. Though been a 90 the bar won't need bending. So that'll make it easier.

Grippa · Mar 28, 2008

redhand said:
They look good If you've got the templates on a cad package can you email them to me as I wouldn't mind knocking one up for myself. Though been a 90 the bar won't need bending. So that'll make it easier.

FFS Pikey, git yerself a bit of cardboard (yer bed'll do) & draw yer own!

Simon72 · Mar 28, 2008

redhand said:
They look good If you've got the templates on a cad package can you email them to me as I wouldn't mind knocking one up for myself. Though been a 90 the bar won't need bending. So that'll make it easier.

I will see what I can do at work on monday for you, not sure if our cad team did them as a CAD file or TRUMPH LASER file, I will find out. PM me your E-mail ;-)

If they are a TRUMPH file I will get them converted.

Grippa · Mar 28, 2008

Simon72 said:
I will see what I can do at work on monday for you, not sure if our cad team did them as a CAD file or TRUMPH LASER file, I will find out. PM me your E-mail ;-)

If they are a TRUMPH file I will get them converted.

If yer do he'll be flogging them on ebay by Tuesday!

Pikey · Mar 28, 2008

Grippa said:
If yer do he'll be flogging them on ebay by Tuesday!

Nah I ain't got access to a laser cutter. mine'll be grinder & a file jobbies. And they'll take too long to be profitable.
.

RAZ8550TDI · Mar 29, 2008

like these???

thats a defender one red, the you wont be able to get the bend on the disco ones as there is also a raise on them aswell as the bend around the windscreen, ill show yer a disco one over the weekend.

Grippa · Mar 29, 2008

Gorra say, s'nice job that.

RAZ8550TDI · Mar 29, 2008

mass production though int it, dont know why there being so cheap trying to make there own.

Simon72 · Apr 8, 2008

Right here is a bit more progress on the light bar and wiring.

I have no pictures of the bar yet constructed due to it is at work being powder coated. Hopefully tomorrow I will be able to show you.

Also got myself 2 sets of brand new RING rectangular driving lights of ebay for £29.00 (WHAT A DEAL)

As you can see I have knocked up a quick relay box and wiring loom (out going feeds not installed yet. (Everything will get silicon sealled once all wires are installed)

Taffy · Apr 8, 2008

if u are selling it on ebay for less then 45 quids make one for me?? my disco could do with one! -)

RAZ8550TDI · Apr 8, 2008

you have a pm taffy.

Roof Bar Spot-Lights

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