Originally Posted by 04_xlt_4.0_4x4
What does it mount to and can it be made without a welder?
It will need to mount to the Steel portion of the Bumper, or if you can get creative you can design a mounting system that will go to the frame. Most light bars mount through the Tow Ring Holes. check the web for Front Mounted Light Bars.
Yes and no on the welding !
, take some FLAT Stock, a bar of steel, cut it to fit the length you are looking for, maybe the width of the grille opening; (S1).
Cut some smaller lengths (S2) that need to be mounted to the bumper (might be a good idea to get the grille shell out of the way.
Drill some holes in the bumper and on both ends the S2 smaller lengths of flat stock; for mounting S2 to the bumper. the position of the S2 Smaller Lengths will depend on where you want the lights and what is under the steel portion of the bumper.
Steel piece S1 can be drilled to match the holes in S2 after S2 has been positioned on the Bumper.
All can be bolted together; after you have cleaned up the edges, rounded the corners and smoothed the drill holes, remember QUALITY First.
You will need to paint the pieces after trial fit; use a good quality Etching Primer, then a good quality Paint from the same manufacturer as the primer. I use DuPont, good stuff.
The Hardware will also need to be painted but it will rust, easiest way to fix that is use stainless steel, even S/S will rust some so don’t be surprised but it will be a lot less than std steel.
Bolt it back together after painting and you have a light bar for the front.
, welding it all together will make for a stronger unit, no rusting in the hardware department at all and once will should give you years of life. This process will take most of the steps above but no drilling for bolts except the Bumper mounting or maybe some clamps like UnderDogs stuff. Underdog-performance.com
Maybe you can make the pieces and then have a friend weld it up, best done will the parts on the truck.
I’m sure you get the idea, but this is just a quick run through on how to make a quick light bar mounted to the bumper. Chk out UnderDog’s Light Tab, make something along that lines but bent up some to raise the light to the grille level.
if this is confusing sorry, I am doing this when I just got up, no coffee, so keep your mind open. You appear to be mechanical enough to mount the lights to start with so" you can do it”.
Here are a few location and parts to look at: (Pics aren’t the best but you get the idea).
4x4, 5sp, Std Cab, Stepside, E4 Red
4” Lift - Coil-Overs, 6” SkyJacker Leafs - No Blocks (Mistake)
31 Spline FX4 Rear Axle, 4.56s and OX Locker, Hurst Shifter w/Optional Stick and "Made by Grev" alignment adapter