1/8 inch tread plate
made a cardboard template traced it on the metal with a silver pencil

cut it out with a plasma cutter....found it on craigslist 250 bucks

cut out the reverse for the other side
before you put them on the jeep put masking tape or something else on the jeep to protect the paint cause you will be putting them on and off alot till you get the bend just right

draw lines on the back where the bends will beging and end....score it with a cut off wheel on your grinder it will help you bend the 1/8" plate easier

put it in a vise and start to hit with a deadblow hammer and start to make the bends this will take awhile to figure out the first one but second one is much easier

once you have the bend then you can do some measurements and figure out where the holes need to be drilled "after you figure out where to drill use a small drill bit and hold it up to make sure you you measured correctly then drill with bigger bit

after both sides are done its time to figure out how high you want your light bar cut the section

i made it a little longer at the winshield so you can work the metal and then you can cut it to the right length later

cut the angles with a chop saw then weld it up

if you dont like the sharp look of the 90 degree angle the cut a cresent shape out of the corner
then you can heat it up and bend it around with a hammer and it will make it round which i like it that way thats totally up to you

after you get it rounded off the cut off the excess i left an inch before the bend starts

do the other to match

measure where you wat the light bar to attatch to the bracket you made then tack weld while on jeep do not weld it fully on the jeep you will blister the paint....oh i laid some towels on the jeep hood so if i dropped anything it wouldnt scratch it.....take off the bracket and finish welding it
the hard part is getting the winshield angles right on both thats why you just tack it then adjust it the finish welding
once the you have it welded and it looks like you want it then cut the 90 degree cuts at the top of the bracket

well i ran out of time this weekend I ordered the lights that i wanted so next weekend i can do the top bar and the tabs
i will finish the write up next weekend
6 hours invested so far

 

thanks,i will........ i would have had it finished today but had to go to the deer lease and get stuff ready for bow season

 

nice looks great so far... look forward to the finished light bar.. great job

 

Hella 500 Black Magic Driving I like that black look.....so this is what im going with right now and later i will move them and probably go for the lightforce 140's when i can afford them....just got new whells and tires....pics to come

 

yeah thats one sweet jeep
I hope mine turns out half as good as yours did

 

thats cool....i will weld a piece of plate from the bracket to the pipe so there should'nt be any flex at all....I will plasma cut a cool design in it for added flash...lol

 

Very cool, sn00wman. Looking forward to checking it out when you get it done!

 

Looking very cool so far. Can't wait to see how it goes.

 

anyone know what the total lenght of the hella 500 black driving lights is from the top of the light to the bottom of the mounting bolt?

 

good looking work so far,