Heres how I made mine, probly would need to be fabed a little different though. it needed some kickers to support it some, and maybe not be attached to the tool box. actually im sure that with the support from the kickers going back to the bed rails that it would be a hole lot stronger, anyway, to the pics.
I had grade 8, (the bolts we had in the shop at the time), going through the tool box, on 4x4 3/16" plates welded to the thickwall 1" tubing. thickwall being 3/16" thick. it had 2inch spacers on it so I could open the tool box.
Here you see where I welded the 3/16 plate to the tubing to hold the light bar. I got the lights and light bar for free, had a gutter mount off a K5 blazer, the mounts were screwed so just used the light bar, you could probly just use c-channel, would be a lot stronger than the alum. that kc makes.
the back end. you'll have to excuse the mess in the bed, was cleaning my tool box out that day. lol.
and the front end.
Im sure like I said before, you would want to make some changes to it, like maybe bend some tubing, or add some more angles, that flow with the body lines better. When I did it I was looking for function, not necessarily looks, you cant tell from the front though. Definelty I would recommend putting kickers or supports of some type on the top of the bar. with mine on the tool box, it broke the welds from it flapping back and forth on the interstate, thats why I took it off, well, also couldnt fit in the parking decks here at school either too well, I could, but didnt feel safe, had to avoid the speed bumps, to much hassle. Theres an idea for ya to fab up though. good luck on what ever you do.
Custom Light Bar
