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Old 05-30-2009
Ford04Ranger4.0's Avatar
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Icon5 Front Light Bar

So I'm thinking of making a light bar that holds 4 Hellas. I have the tabs from underdog but the pre drilled holes dont hold the Hellas well and was wondering how to do this. I was thinking of welding washers on te tabs to secure the Hellas better and getting a piece of angler iron and drill 4 holes that fit the Hella bolts. Any ideas or inputs?
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Old 05-30-2009
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get a piece of angle iron around 30-32" long. Lay it over the tabs, then go underneath and mark the hole location into the the angle iron. Drill those two holes (to bolt to the tabs) along with 4 more for your lights.

The only issue you will have is the tabs have too much metal in front of the holes. You will most likely have to cut 1/2" or more off the tab. It will be self evident when you set the angle iron on it. If thats not pratical you could bolt the angle iron underneath, but it might look bad.
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Old 05-31-2009
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Yea I saw what Shane did, it'll kinda be like his. The only thing that sucks is the tab holes are so big and the Hella bolts are like 3x smaller. So I'm thinking of welding a washer under and above the tab big enough for the Hella bolt and big enough for the hole. To secure it tight. I got a 3ft piece of angle iron from Lowes and another switch.

Another option I thought of is cutting the tab off before the hole. That way I know the angle iron will fit flush and pull the lights closer to the grill also I'll drill the right holes for the Hella bolts.
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Old 05-31-2009
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just drill 6 holes in the angle iron. 2 for the light tabs and 4 for your lights. that way you can mount the lights where you want them.
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Old 06-01-2009
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not sure if this is what you have in mind but here's mine.
Name:  Hellas002.jpg
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Old 06-01-2009
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Bob thats what I have in mind but going to use the tabs instead of drilling in the bumper
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