How-To: Mount a Lightbar in Grille
 

I drive quite a bit at night in the backcountry and the light output on the ranger is just pathetic, so I set out to build a grille light bar setup since there is nothing commercially available. It took me way too long and way too many iterations but I finally got it done so I thought I would post it up since no one has done a DYI that I have seen.


I wanted as factory of a look as possible and I think it ended up pretty decent.

https://cimg1.ibsrv.net/gimg/www.ran...cf75c2b85a.jpg

https://cimg7.ibsrv.net/gimg/www.ran...bf322d3f03.jpg

I took a look at the various grilles and the 04-05 sport grille had the largest opening and was the easiest to work with and modify. I cut out the entire center section. I then used the grille and the rad support measurements to fabricate a lightbar bracket.

https://cimg1.ibsrv.net/gimg/www.ran...922fed85e9.jpg

I modified the opening behind the grille to fit the bracket I fabricated. I cut out the center post though it ended up being unnecessary. I also had to move the transmission cooler down lower. I took the opportunity to spray undercoating on everything to freshen things up.

https://cimg8.ibsrv.net/gimg/www.ran...262e7d1375.jpg

https://cimg0.ibsrv.net/gimg/www.ran...1daf7abce1.jpg

I opened up the lightbars and siliconed them up nice and watertight.
I didn’t want a rat’s nest of relays under the engine compartment to rust and degrade and that’s when I noticed that the power junction box under the hood is modular. I went the junkyard and picked up the necessary modules and wired them in for a clean, water-resistant setup.

https://cimg3.ibsrv.net/gimg/www.ran...eb291332b1.jpg

https://cimg5.ibsrv.net/gimg/www.ran...3e54a827bf.jpg

I took a sheet of fiberglass, shaped it, and then mounted it to the front of the bracket to minimize the lightbar’s exposure to the elements and make them far easier to clean when dirty. It also gives the install a nice pro install look.

https://cimg7.ibsrv.net/gimg/www.ran...64cbeda457.jpg

The amount of light the lightbar’s throw is amazing. I am so glad I finally did the job despite the fact that I could have likely engineered an entire truck in the time it took me to sort this damn thing out.

https://cimg8.ibsrv.net/gimg/www.ran...7bb8eb5da9.jpg

Close up pics of the modified grille please?