Hi-Lift Roll Bar Mount Write Up for Unlimited JK
Thread Starter
JK Newbie
Joined: Oct 2007
Posts: 93
Likes: 0
From: Boulder City, Nevada
Hi-Lift Roll Bar Mount Write Up for Unlimited JK
Unlimited JK Hi-Lift Roll Bar Mount Write Up
What is needed:
1.5” x 1.5” .120” Wall Square Tubing 2- .5” Hex Nuts
2- .5” Grade Five Bolts 4” Long 2- .5” Wing Nuts
1- .5” Lock Washer (2 optional, if not making a locking mount)
4- .5” Washers
Getting Started:
I had to figure out the angle of the roll bar (which was 62.5 degrees). Therefore the angle of the cut in the square tubing will be at 27.5 degrees to bring it to 90 degrees.
1- Remove the roll bar covers and padding in the back.
2- I started with a foot long piece of square tubing, and I cut it about in the middle at approximately 28 degrees.
3- I used a belt grinder to bring it to the proper angle and removed the burrs.
4- Once you have the proper angle, cut your piece of steel to approximately 1.5”. This will be the base of your bracket.
5- Use a drill press with a vice and drill a .5” hole centered towards the bottom (the wide part) of the bracket.
6- Repeat steps 3-5 for second bracket.
7- Take one of the two bolts and place it securely in the vice on the drill press and drill a 3/16” hole towards the threaded end of the bolt (do this only if wanting to put a padlock through the bolt). Clean the threads around the hole with the wire wheel on a bench grinder.
8- Push bolts through the bracket from back to front. Make sure bolt with hole has the hole facing the way you want it to (I chose from left to right).
9- Weld the head of the bolt to the back of the bracket. Grind weld if needed.
10- You will need to compare your jack to the roll bar. I suggest finding your own measurements instead of just using mine. The bend in the roll bar leaves approximately 26” of flat area for your brackets to be mounted within.
11- Measure from each end of your jack and mark a hole evenly spaced from each end. Ensure the holes are less than 26” apart. I chose the hole between 11.5” and 12”.
12- Place a hex nut on each bolt. Thread until the threads stop and place a washer on top of it.
13- Put the bolts through the marked holes. Place the other washer on it and tighten with wing nut. Make sure your brackets are facing the proper direction (narrow part towards the jack handle).
14- Remove the roll bar cross member (8 bolts-4 on each side).
15- Hold jack with mounts against the roll bar and mark where the brackets are on the roll bar and sand the paint off of these areas.
16- This part will be a two person job. One person will have to hold the jack (with the brackets) in place while the other person (preferably with welding skills) tack welds the brackets in place on the roll bar.
17- Remove the jack from the brackets and weld around the perimeter of the brackets.
What is needed:
1.5” x 1.5” .120” Wall Square Tubing 2- .5” Hex Nuts
2- .5” Grade Five Bolts 4” Long 2- .5” Wing Nuts
1- .5” Lock Washer (2 optional, if not making a locking mount)
4- .5” Washers
Getting Started:
I had to figure out the angle of the roll bar (which was 62.5 degrees). Therefore the angle of the cut in the square tubing will be at 27.5 degrees to bring it to 90 degrees.
1- Remove the roll bar covers and padding in the back.
2- I started with a foot long piece of square tubing, and I cut it about in the middle at approximately 28 degrees.
3- I used a belt grinder to bring it to the proper angle and removed the burrs.
4- Once you have the proper angle, cut your piece of steel to approximately 1.5”. This will be the base of your bracket.
5- Use a drill press with a vice and drill a .5” hole centered towards the bottom (the wide part) of the bracket.
6- Repeat steps 3-5 for second bracket.
7- Take one of the two bolts and place it securely in the vice on the drill press and drill a 3/16” hole towards the threaded end of the bolt (do this only if wanting to put a padlock through the bolt). Clean the threads around the hole with the wire wheel on a bench grinder.
8- Push bolts through the bracket from back to front. Make sure bolt with hole has the hole facing the way you want it to (I chose from left to right).
9- Weld the head of the bolt to the back of the bracket. Grind weld if needed.
10- You will need to compare your jack to the roll bar. I suggest finding your own measurements instead of just using mine. The bend in the roll bar leaves approximately 26” of flat area for your brackets to be mounted within.
11- Measure from each end of your jack and mark a hole evenly spaced from each end. Ensure the holes are less than 26” apart. I chose the hole between 11.5” and 12”.
12- Place a hex nut on each bolt. Thread until the threads stop and place a washer on top of it.
13- Put the bolts through the marked holes. Place the other washer on it and tighten with wing nut. Make sure your brackets are facing the proper direction (narrow part towards the jack handle).
14- Remove the roll bar cross member (8 bolts-4 on each side).
15- Hold jack with mounts against the roll bar and mark where the brackets are on the roll bar and sand the paint off of these areas.
16- This part will be a two person job. One person will have to hold the jack (with the brackets) in place while the other person (preferably with welding skills) tack welds the brackets in place on the roll bar.
17- Remove the jack from the brackets and weld around the perimeter of the brackets.
Thread Starter
JK Newbie
Joined: Oct 2007
Posts: 93
Likes: 0
From: Boulder City, Nevada
Unlimited JK Hi-Lift Roll Bar Mount Write Up Cont.
18- Remount the roll bar into place.
19- Push roll bar foam padding into place push on it hard to indent where the bracket is and remove it again. With a knife cut the padding so the bracket will fit into it and replace back onto roll bar.
20- When putting the roll bar cover back on you will have to remove the two hex nuts from the newly fabricated brackets and cut slits in the roll bar cover where the bolts will protrude through.
21- Once the roll bar cover is back on, put the two hex nuts back on the bolts and tighten with a ¾”wrench.
22- Place a washer on each bolt.
23- Put jack into place on your new mount. (bolts should line up with marked holes)
24- Place washers and lock washers into place (you will not be able to use a lock washer if using a padlock on one side).
25- Secure with wing nuts.
26- Lock one side with small padlock.
That's it!
Back seat passengers won't hit their heads on the jack.
Hard top fits perfect.
And voila! It’s as simple as 1,2,3…26. And you have an awe inspiring new Hi-Lift mount to go with your awe inspiring Unlimited JK.
19- Push roll bar foam padding into place push on it hard to indent where the bracket is and remove it again. With a knife cut the padding so the bracket will fit into it and replace back onto roll bar.
20- When putting the roll bar cover back on you will have to remove the two hex nuts from the newly fabricated brackets and cut slits in the roll bar cover where the bolts will protrude through.
21- Once the roll bar cover is back on, put the two hex nuts back on the bolts and tighten with a ¾”wrench.
22- Place a washer on each bolt.
23- Put jack into place on your new mount. (bolts should line up with marked holes)
24- Place washers and lock washers into place (you will not be able to use a lock washer if using a padlock on one side).
25- Secure with wing nuts.
26- Lock one side with small padlock.
That's it!
Back seat passengers won't hit their heads on the jack.
Hard top fits perfect.
And voila! It’s as simple as 1,2,3…26. And you have an awe inspiring new Hi-Lift mount to go with your awe inspiring Unlimited JK.
That's a very pretty looking and functional setup you have going there.
JK Freak
Joined: Jul 2007
Posts: 520
Likes: 0
From: Ellijay, GA
Wow i think you are bad ass for coming up with this mod and badass for tig welding in a tank top!!!! I made the mistake of doing it in a short sleeve shirt last friday and im still paying for it in the bends of my arms.
JK Enthusiast
Joined: Feb 2008
Posts: 134
Likes: 0
From: Savannah, Ga
