angle iron, the anti shake?

[wagonryan]

kso to start it off, I made my light bar like six months ago and it holds 4 hella 500's

http://i300.photobucket.com/albums/nn30/ryaneggers/July2009.jpg

My bar is made out of angle aluminum or zinc plated steel and its pretty flimsy.
When fully tightened, it shakes a little bit on rough stuff, but as time goes by it gets really loose.

I would like to keep the same general design seeing as how I hacked the plastic s h i t out of the bumper and it would be empty without the lights.

I have it attached to the mystery holes in the bumper beam and am wondering if angle iron would be better. it seems like it would be stronger, but also more heavy. where does the sturdiness of the bar start to suffer because it is too heavy and gets shaken loose a lot easier??

cheers

[ozdewiz]

In our rallycars, years ago, we used to use adjustable bars attached to the radiator panel (Through the grille)
They were then attached to the top of the spots (One each)

This stopped a lot of the shaking we were getting
As well as saving $$ on bulbs, from them being shaken while in use & blowing

As for your conundrum, you already have a working bar you can use to manufacture another bar, it's just needs a cuppla things to get it right

Use slightly thicker Alum
(We used 25mm x 25mm x 5mm angle){25mm = 1 inch}

Get a friend to TIG weld it together
(& make a jig to hold it all so it doesn't warp as it's being welded)

Use weather-proof adjusters
(We used 9 inch long guy-wire adjusters) {The type used on roofs to hold tall aerials up}

[gwilson87]

I had the same problem with the light bar on my brat. Thin material caused the lights to bounce all over the place. Thicker angle iron would for sure help with the sturdiness, and if the bolts are coming loose maybe throw on some red lock-tite and some of those fancy lock washers to grip pretty good. Best of luck.