New Light Bar Prototype!!

[fattie92]

Well I got bored and wanted to make a new light bar. Wanted something simple that uses existing bolt holes and hardware... This just a prototype to see if I would like it and how sturdy it would be. The angle iron I used will not be on the real deal. I hate that holed up crap.

http://i91.photobucket.com/albums/k316/fattie92/DSCF1342.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1340.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1343.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1346.jpg

The light spacing is off... Oh well, just a mock up.
http://i91.photobucket.com/albums/k316/fattie92/DSCF1350.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1349.jpg

[lorenkb]

I take it you bolted it on using the license plate mounts as well? Cool implementation. Painted to match the body would look really nice (aside from the angle iron :D )

Loren

[BlueRu]

I like it. Its simple and functional. When you get the real deal made up could you post a pic of the light spread?

[fattie92]

This bar is easy and simple. As you can see, it uses your existing radiator support bolts, and the 2 license plate screws. You should see how complicated my existing light bar is! Like I said, this isnt the final draft, just kinda thrown togeather to see how it would turn out. Its painted in grey primer just so it would stand out more for pictures. My original idea was to make something that was cheap and easy to make, uses all stock holes and bolts. If it turned out nice enough, I planned on making a few and selling them.

[BlueRu]

IMO this is a very nice looking rack (even with the holed bar). If you do make some to sell I may be your first buyer.

[409industries]

Pretty sweet man! i like the concept, id love to see the finished prototype

[Blix666]

does this setup bounce? it looks rather....rickety

[I Like It Sideways]

I like the idea, simple, and it looks like it works.

[fattie92]

does this setup bounce? it looks rather....rickety

Not positive yet. Just bolted up like I had it, it was sturdy. I am going to try to get the final product done tonight/tomorrow if all goes well. I got some metal I found in my garage I want to give a shot.

What does everyone thing about paint? White or Black?

[BlueRu]

I would go black.

[Blix666]

+1 for black

[409industries]

Id definitely go with the black. I too would be interested to see how the lights do as far as shaking on a washboarded dirt road...

[fattie92]

Id definitely go with the black. I too would be interested to see how the lights do as far as shaking on a washboarded dirt road...

Dont have anything like that around here. Id have to wait 2 weeks for the next race to find something like that.

[Not All There]

or just send me a prototype hahaha

[BlueRu]

or just send me a prototype hahaha
Im in the same condition. If you sent me one I could test it for you....................and keep it LOL. J/K. dont send it to me thats a bad idea.

[fattie92]

I would be willing to work something out if all goes well :wink:


I didn't really get to work on it tonight. BUT, I did figure out a design change that I will be making. From the get go I was not to happy with the openness of the light bar. I don't like how you can see the bolts..So I am going to box that in. I cant find metal like I want, so I will have to take two pieces of the angled steel and weld them together. That way the front will be closed off, as will the top and back, but leave the bottom open for easy adjustments. I will have to drill two holes in it though so you have access to your license place screws.

[fattie92]

Do any of you even have lights to put on one of these for testing?

[BlueRu]

Do any of you even have lights to put on one of these for testing?
No. I just figured that those would come with the bar to "test." Lol. I cant wait for you to get a working proto. And possably ones to sell.

[Not All There]

I run some lightforces..
http://i88.photobucket.com/albums/k191/NATRacing/NAT%20Rally%20Project/Air1.jpg

But I dont believe your mount will line up the same on my 95 which sucks.

[fattie92]

Ah yeah, this will only work on 04-05 wrx's as far as I know.

[fattie92]

This is starting to look pretty damn good, WAY better then the first mock up... I think I need to order some Dirty Impreza.com stickers to put on it now...

[fattie92]

Damn this thing turned out to be BEEFY! All I have left are to drill the holes for the lights and paint it...SHOULD have some done pics tomorrow!

[409industries]

nice. post em up when you're done!

[fattie92]

OK, didn't get it all done. Due to rain and a drill issue, I did not get it completely painted. Its all drilled and welded. Mounted the lights and they are all spaced even. Now I just gotta finish the paint process.

Here are some spy pics just so you can get an idea...
http://i91.photobucket.com/albums/k316/fattie92/DSCF1354.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1355.jpg


So, what do you think? Better then the first one?

[BlueRu]

Most definatl better then the first one. I like it and want to know when you get the second one made, so I can buy it. Do you know if it will fit an '03 rex?

[fattie92]

Most definatl better then the first one. I like it and want to know when you get the second one made, so I can buy it. Do you know if it will fit an '03 rex?

I have no clue. I dont have a bugeye to experment on anymore since my buddy traded his in for an STi. I can see it MIGHT work. Maybe I can try to find a local bugeye to work on... Offer the guy a free bar or something.


You can meet me in michigan and we can test fit it! :lol:

[Blix666]

hey fattie...just curious as to why you don't like your current light bar.

[fattie92]

hey fattie...just curious as to why you don't like your current light bar.

Its not that I dont like it... Just bored with it. There are some little things with it as well that bug me, but overall that bar is freaking awesome! I hit a racoon at 70mph with that thing and not a scratch to it or the car.

The main reason for making a new one was because I think there is a demand out there for decent CHEAP light bars. So I thought I could take a stab at coming up with a nice, clean design that is easy to bolt on, and easy to make. If I was succesful, I planned on making a few, and selling them on forums and ebay. The current bar that I have is complicated as all hell, and does not use existing bolt holes. I ended up having to drill my core support to bolt it up.

I also planned on a 2 part system. My current bar is a light bar/crash bar all in one. My idea for this one is to have a light bar and a crash bar seperate. So I can bolt up the crash bar for some cone bashing on race day, then take it off if I want, but still have my lights on.

I just look for reasons to cut, bend, and weld ****. :twisted:

[409industries]

I think its coming along nicely!

[Blix666]

freakin' sweet

[BlueRu]

Most definatl better then the first one. I like it and want to know when you get the second one made, so I can buy it. Do you know if it will fit an '03 rex?

I have no clue. I dont have a bugeye to experment on anymore since my buddy traded his in for an STi. I can see it MIGHT work. Maybe I can try to find a local bugeye to work on... Offer the guy a free bar or something.


You can meet me in michigan and we can test fit it! :lol:

Lol. That would be a fun drive. Alas, I dont have the cash to drive that far. :(

[fattie92]

OK, got it painted and mounted.. I think it looks pretty good! Gotta wait till the night time comes to test it out.

http://i91.photobucket.com/albums/k316/fattie92/DSCF1357.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1356.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1358.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1359.jpg
http://i91.photobucket.com/albums/k316/fattie92/DSCF1361.jpg

[BlueRu]

It looks very good. I can't wait to hear how good it works.

[fattie92]

it works fine. There is some light shake, but it is not to bad. So far so good!

[UP2MTNS]

it works fine. There is some light shake, but it is not to bad. So far so good!

light shake....hmmmm....looking at that last picture, what if you put some long spacers between the front bumper and back of the L bracket, and lined them up with the holes for the license plate?

That way you reduce the shake, but don't have to drill holes in the bumper. They don't have to be as solid as mounting bolts, just enough to zero-out the 'shake'?

The holes that are already there....did they come like that? They look *almost* lined up already...but not quite?

[fattie92]

it works fine. There is some light shake, but it is not to bad. So far so good!

light shake....hmmmm....looking at that last picture, what if you put some long spacers between the front bumper and back of the L bracket, and lined them up with the holes for the license plate?

That way you reduce the shake, but don't have to drill holes in the bumper. They don't have to be as solid as mounting bolts, just enough to zero-out the 'shake'?

The holes that are already there....did they come like that? They look *almost* lined up already...but not quite?


I guess it is hard to tell in the pictures... The light bar itself is basicly square stock with the bottom cut out. So its pretty much like a U ... The back side of that bar is sitting right on the bumper. Then there are holes in it so I can screw in the plate/help secure the bar. The holes on the outside that you see are so you can stick a screwdriver in there to tighten it up.

I really got to test out the new bar this past weekend in Michigan. I got to go down some washboard dirt/gravel roads. The light shake really is not bad at all.

Next week I plan on making 2 and TRYING to sell them... What do you guys think? If I make them a little better, do you think they will sell? What would even be a good price for it?

[UP2MTNS]

i'm not sure about the price....but I do know there isn't much out there in 'economy' light bars. If these are easy and fairly inexpensive for you to fab up, you'll do well keeping the price lower (less than $100?) and selling higher volume.

I'm looking for a few light bar set up as I kind of f'd up mine this past weekend. I'm gonna search around a bit, but I might be interested. I'll be following this thread a little closer now :)u

[fattie92]

I was thinking about just making a couple, selling them to a few people for CHEAP, just so they can test it out for me and provide me with some feedback. Then after that, if all is well and the test dummies give it the stamp of approval, I will make some and sell them at full price.

If you are interested in being a test dummy, let me know and we can work something out. I only ask that you USE IT!

I am also a little concerned with the license plate holes. I need to get my buddy over here so I can see how the holes line up on his STi.

[UP2MTNS]

I was thinking about just making a couple, selling them to a few people for CHEAP, just so they can test it out for me and provide me with some feedback. Then after that, if all is well and the test dummies give it the stamp of approval, I will make some and sell them at full price.

If you are interested in being a test dummy, let me know and we can work something out. I only ask that you USE IT!

I am also a little concerned with the license plate holes. I need to get my buddy over here so I can see how the holes line up on his STi.

yeah, PM me and lets figure something out. Don't worry, I USE it...haha. You should see what I did to my rally innovations light bar.... :roll:

[fattie92]

I was thinking about just making a couple, selling them to a few people for CHEAP, just so they can test it out for me and provide me with some feedback. Then after that, if all is well and the test dummies give it the stamp of approval, I will make some and sell them at full price.

If you are interested in being a test dummy, let me know and we can work something out. I only ask that you USE IT!

I am also a little concerned with the license plate holes. I need to get my buddy over here so I can see how the holes line up on his STi.

yeah, PM me and lets figure something out. Don't worry, I USE it...haha. You should see what I did to my rally innovations light bar.... :roll:

Lets see it!! I am guessing you hit something? This one is up high, so no need to worry about broken lights!

[409industries]

UP2MTNS rally innovations light bar is pretty F'ed :)

[fattie92]

...waiting on pictures

Sounds like he could use my crash bar when its done too!

[fattie92]

Just a quick little update....

I have had this bar on for 3 weeks now and I must say I am extremely happy with it! As I stated before, there is a little bit of light shake, but for the simplicity and looks of the bar, I do not mind it one bit. The only 2 problems I have had with it to date are the paint where the hood seal touches the bar is rubbing off, and I had to step up to beefier license plate screws. I am also going to change the paint up some. I am going to use a special under body paint that has some texture to it. The stuff is super strong, and just looks tough.

Here is the paint that I am thinking of using. I painted my first lightbar with it and was very happy with it!
http://i91.photobucket.com/albums/k316/fattie92/DSCF0659.jpg

[409industries]

yeah that paint looks like its there to stay for good...

[fattie92]

Test fitted on my buddies STi last night! Fits like a charm!! The license plate screws were a SMIDGE off.... Should still work. Working on pics.

[shakes]

I would suggest going and talking to a powder coater. The powder coat will last much longer and take more abuse then paint will. There isn't much to the light bar, so if you do it in bulk (10 or so), it really shouldn't cost you much more then the paint would. You can do powder coat in wrinkle finish as well.

[fattie92]

Id rather spray it with this underbody paint. Its tough as hell, and I can get it CHEAP. Trying to keep costs down to make it a true economy light bar.

[fattie92]

Oh hell no! I went to a different Home Depot today after work to get some more metal, and what do I see?

You guessed it!! Thicker, stronger metal for the 2 supports going to the radiator bolts!

What does this mean you might ask? Easy, this will help to eliminate some light shake!!

I am jealous though, I will not even be the one to test this new metal out...As I have to make them, test fit them, paint them and ship them... :shootsself:

[Blix666]

you're already sellin'em?! wow.

[fattie92]

you're already sellin'em?! wow.

Ehh not exactly. I have a few people that are going to test them for me and tell me what they think before I start to advertise them.... They are all on this board too!


I ran into a snag with this thicker metal. I can not bend it the way I was bending the thiner stuff. So now I am using my friends metal bender, which means all the measurements are different.... Getting there.. Slowly... It will be a kick ass bar when I am done though! Economy bars FTW!!

[UP2MTNS]

you're already sellin'em?! wow.

I'm one of the first test case(s) w/the new metal. I'll be sure to post a little write up/take pics for everyone!

[fattie92]

I am picking up some new tools this weekend!!... Drill press, and metal bender FTW! Now I can get cranking on these and not depend on a friend.

[BlueRu]

Cool man! I wish I had lights to be a tester. Dangit!!!!!!!!! Oh well. I will just wait until you sell them to get mine.

[UP2MTNS]

I am picking up some new tools this weekend!!... Drill press, and metal bender FTW! Now I can get cranking on these and not depend on a friend.


god damned I want a garage!!!!

[409industries]

Dood that is sick that youre already getting these mailed out to people. Hopefully UP2MTNS will have his on when i see him at the end of the month. I wanna check this thing out!

[fattie92]

Quick question for everyone.... I know everyone runs a different light setup, so I am curious about the hole spacing. I am going to drill them for my current light setup, but am toying with the idea of adding additional holes for different spacing. The bar itself is 25" long. So I can do 6 inch even, then my current spacing (cant remember what mine is at) .... Anyone think of other offests I should do?

[UP2MTNS]

Quick question for everyone.... I know everyone runs a different light setup, so I am curious about the hole spacing. I am going to drill them for my current light setup, but am toying with the idea of adding additional holes for different spacing. The bar itself is 25" long. So I can do 6 inch even, then my current spacing (cant remember what mine is at) .... Anyone think of other offests I should do?

my lights are 6 1/8" diameter, so I would need wider than 6". Your lights are 6" diameter right? What is the current spacing?

http://www.kchilites.com/kcproduct_images/pairpacks/Slim-Dim.gif

[fattie92]

I forgot what mine is... I am thinking of maybe just drilling a hole every 3 inches or so.

[Blix666]

i would set it up for 4 lights going across with an additional hole in the center of the bar for those who would like to run 3 lights.you could do the hole every 3 inches or so, but personally, i think it'd look lame. it would just look like that cheezy angle iron that you buy at the depot for all uses.

another option would be to leave it up to the person ordering the bar. you can pre-make all the light bars with no holes in them then custom-drill all of the holes when ordered. that will give the bar a more tailored look.

[fattie92]

i would set it up for 4 lights going across with an additional hole in the center of the bar for those who would like to run 3 lights.

Not everyone runs the same size lights though. Mine are spaced perfect for my 500's and ff1000's. Somone might want 4 KC's on there, or 4 500's... The spacing would just not be right and they would complain or have to drill into there new light bar.

[Blix666]

i don't think you should just drill a bunch of holes though.

personally, i would drill'em to order.









your car is sick! :D

[UP2MTNS]

i don't think you should just drill a bunch of holes though.

personally, i would drill'em to order.




+1 I agree.

[fattie92]

i don't think you should just drill a bunch of holes though.

personally, i would drill'em to order.











I think that can get ugly, and fast. I can see people bitching because of the spacing being wrong or something.... I dont know, I will toy with it and see.

[kreitz3]

Drill your own holes when you receive the product FTW.

[fattie92]

Drill your own holes when you receive the product FTW.

That is going to be an option when I make them. There will be a few cheaper (like its not going to be cheap enough!) options for the DIY'ers. I will offer them unpainted (primed for rust protection), and a drill your own light holes.

As for drilling to order.... I decided that I do not like that idea. I can just see someone screwing up there measurements and then putting all the blame on me. I honestly don't think that it will look to bad with multiple holes on the top. Wont be able to tell till I do it though..... I think I am putting to much thought into this...

[fattie92]

bar is 25" long (could make it a bit longer... say 26-28"?)

My 500's are 6.32" in diam.
My ff100's are 6.88" in diam.

Spacing goes like this... -> |500| 8" |FF| 9" |FF| 8" |500|

[Weasel Rallysports]

Do you think this is sturdy enough to hold 4 Rallye 4000's. If so, I'm definately interested, because I'm wanting to have a removable mount for mine, and the better half says no way to light pods, dang. I live close to where they used to run the Sunriser 400 ProRally, and still like to go out and play on those roads.

[fattie92]

Do you think this is sturdy enough to hold 4 Rallye 4000's. If so, I'm definately interested, because I'm wanting to have a removable mount for mine, and the better half says no way to light pods, dang. I live close to where they used to run the Sunriser 400 ProRally, and still like to go out and play on those roads.

Damn, thats a BIG light! 8.75 in diam. I think it would hold them just fine, I would have to make the bar longer though. Id need to make it like 35" long for you..... Hmmmm.... I think we can work something out if you want.

[james.c.obrien]

Dammit, people...I don't even have the car yet and I'm already looking for two pair of PIAA 580s to put on it :mrgreen:

Have you figured out pricing yet? I'd be more than happy to help you test it on an '07 WRX wagon.

[fattie92]

I have a idea on prices, but nothing is set yet. I will not put a price out there till my testers get back to me, and in order to do that, I need to get the bars out to them.

As for your 07'... I need to find a 06-07' local to look at so I can come up with ideas. Right now I am only making things for the 04-05's. In time I will get them all covered.

[fattie92]

:D This is starting to look GOOOOOOOOOOOOOD!

[409industries]

Do you need anyone to donate a GC/GM? I'd be down to be a tester... ;)

[fattie92]

gotta come over so I can fab one up for you!

[409industries]

gotta come over so I can fab one up for you!

hah, well my RS is registered in IL still... id be a good excuse to come out.

[I Like It Sideways]

I'm excited to see the finished product... and would definitely consider purchasing one. Just read through all the previous posts. Great progress with this project. If my RS was up and running, I'd be game for coming on over for a GC test fit.

[fattie92]

Here it is guys! Sneak peak of the new design! Tell me what you think!

(My good camera broke, so I have to use my backup POS camera....sorry!)

Here you can see the universal holes.
http://i91.photobucket.com/albums/k316/fattie92/P7170160.jpg

Check out the contour!! Also, nice THICK supports!
http://i91.photobucket.com/albums/k316/fattie92/P7170158.jpg
http://i91.photobucket.com/albums/k316/fattie92/P7170159.jpg

[BlueRu]

Thats Fkn SWEET!!!!! I cant wait for you to find a bugeye to mod to fit. Then for you to make some and then for you to sell it to me!

[fattie92]

OK, this is NOT an easy task.... Getting to be VERY frustrating.

[fattie92]

UPDATE... If anyone is still watching this thread.

I finally got my own mounted on my car and tested out. There is still a little light shake, but I only noticed it on my FF1000's. My 500 fogs are rock solid. This leads me to believe that the fault may be with the lights them self, and not the actual bar. Only time will tell when my testers get back to me about how its working for them.

[UP2MTNS]

you got my paypal, yah?

[409industries]

Looking sweet!!! im interested in one for the RS

[fattie92]

Only if I had an RS to make one for...

[409industries]

Only if I had an RS to make one for...

I might have to post on rs25.com to see if theres any people in your area that might be interested!

[fattie92]

That could work...hmmmm

[I Like It Sideways]

Very nice work!!! I like how this looks!!!

[kreitz3]

Hey Ryan. I didn't even realize you were at the Detriot season opener until I saw some pics today. I've probably talked to you.

[fattie92]

Hey Ryan. I didn't even realize you were at the Detriot season opener until I saw some pics today. I've probably talked to you.

Possibility! You going to come up for the Aug 18th race? At Bob's Raceway in Clarksville, MI... Always a good time at Bob's!

I say you show us so I can see if this bar will fit on your car!...... I don't think it will though :x

[kreitz3]

I would come up there for sure, but our next PE is also on the 18th.

[UP2MTNS]

Tell me what you guys think? btw, I forgot about my JDM grille...which didn't let the lightbar fit properly, so I just pulled it off (it was a little beat up anyways). With it totally off, and just the bar and lights on, I kind of like the look. I'm thinking I'll clean up the wires, put a fresh coat of black paint on the radiator/parts, and keep it simple.

thoughts?
http://memimage.cardomain.net/member_images/2/web/2306000-2306999/2306310_62_full.jpg
http://memimage.cardomain.net/member_images/2/web/2306000-2306999/2306310_63_full.jpg
http://memimage.cardomain.net/member_images/2/web/2306000-2306999/2306310_64_full.jpg
http://memimage.cardomain.net/member_images/2/web/2306000-2306999/2306310_65_full.jpg

[Blix666]

that looks friggin' awesome! :shock: :o

[fattie92]

Looks good to me!! How do you like it so far?



Its weird seeing it on other cars then my own...

[UP2MTNS]

Looks good to me!! How do you like it so far?



Its weird seeing it on other cars then my own...

so far, I like it! looks good....easy on/off. I need to re-wire my fog lights, but my driving lights work fine, I just need ot drive around more at night to see how much (if any) light shake is there.

[409industries]

Id be interested to see how much light shake there is. Overall id say it looks awesome! I like it even better than your last night bar...

dope.

[UndercoverObbie]

You said it'd fit an '04 WRX, right? (I saw your answer to that somewhere in this thread, and now I can't find it for the life of me :evil:) If it does, and I get the wagon I've been drooling over, I'd love to buy one of these. Any idea what the price is going to be?

[UP2MTNS]

Id be interested to see how much light shake there is. Overall id say it looks awesome! I like it even better than your last night bar...

dope.

yeah, after seeing what Eli (and others) did to their cars at Gorman, there's no way the RI bar is a functional 'stage rally' light option. It would get ripped off in the first mile. hell, I beat mine up in just a few rally crosses.

[409industries]

Id be interested to see how much light shake there is. Overall id say it looks awesome! I like it even better than your last night bar...

dope.

yeah, after seeing what Eli (and others) did to their cars at Gorman, there's no way the RI bar is a functional 'stage rally' light option. It would get ripped off in the first mile. hell, I beat mine up in just a few rally crosses.

How do you think the new one (fatties) will hold up?

[UP2MTNS]

How do you think the new one (fatties) will hold up?

well, only time will tell.....needs to take a few hard hits. The only thing that makes me a little nervous is the two bolts that screw into the bumper, its not like they're bolted into a steel plate and really tightened down. I could envision them potentially pulling out on a big hit.

[fattie92]

Obviously hitting a immovable object, things will break. As for the screws coming loose, I have had that problem. It was not due to vibration or rough roads though. You just need to make sure that the screws are in "Good-N-Tight"... I had screws in there that were to small. Since I test fit all of these bars on my car, the screw holes got a little loose. I just had to put bigger screws in there and I was good to go. I have had my bar on for a while now. I have had a rallyX with it on as well and nothing has come loose. It sits up high so you gotta hit something pretty big to do any damage to that bar.

Lets just say the screws do come loose and fall out... The lights still will not go anywhere. The 2 main supports will support that thing by them self. The only thing you might experience is some light shake without the screws.

[fattie92]

You said it'd fit an '04 WRX, right? (I saw your answer to that somewhere in this thread, and now I can't find it for the life of me :evil:) If it does, and I get the wagon I've been drooling over, I'd love to buy one of these. Any idea what the price is going to be?

Yes, It will fit an 04 WRX. Prices are still being worked out.



Since I have sent out the prototypes, I have not worked on these at all. I had to step back and take a break because it got to be very stressful. I plan on starting this all back up soon though. I need to find time to get to the steel store to shop around.

[409industries]

Is there a way to possibly use bolts with locknuts and washers to secure the bottom instead of screws through the plastic alone?

[fattie92]

Possible? Yes.

Its something I have thought about doing, but I want to keep this a simple bolt on project and that would make it not so simple. ...."If its not broke, Dont fix it"...

[Blix666]

any new news with this?