I checked on it this afternoon and the paint is sticking a whole lot better so I'm pretty sure the high humidity was slowing the process down. I'm pretty sure the guy I'm going to call about powder-coating sandblasts everything before baking. I'll be sure to ask him though.

 

I decided to mount the bar a few minutes ago and take some pics to show the end results minus the lights. Overall I'm very happy with it but there are a couple things that I will change. I definitely want to move the light tabs up in order to gain clearance for light covers and to move them away from the bumper a bit more. I may also add some length to the mounting brackets so that a wider variety of lights can be used. Most slim lights (IPF 968, Hella 500 series, KC Slimlites, Piaa 520, etc.) will fit fine but some of the deeper lights (original KC Daylighters, HID lights, some Lightforce lights, etc.) may not fit due to the depth from the center of the mounting stud to the back of the light. I wanted this bar to be compact and low profile so I did intentionally make it this way for myself but like I said I might lengthen it somewhat so there's less of a limit on which lights can be used. Not everyone likes to use the same lights.

Anyways here are a few updated pics:

 

wow I actually like how tight you keep it to the bumper. Personally if you decide to make a different one I want dibs on that one...

 

I like the look of that light bar, but I have one question, Could you possibly make one out of stainless for those of us in the rustbelt. Another possibility would be 6000 series aluminum like a 6061. I fully expect a higher price point for either material due to the higher cost compared to mild carbon steel.

 

Well it does look good, one thing I would add the first try on my light bar it would shake and make the light bounce all over the place so I had to make a wider mounting spot than what you have, so you might want to test for that too

But it does look good and if you paint it white it would make the lights look they are mounted to nothing from a distance

 

I do like how it sits close to the bumper as well. I don't really know what lights others intend on using..... that's why I said I might extend the arm somewhat but personally I like it the way it is.

Let me check on materials for stainless. I know I have some sheets of 1/8" stainless at the shop but I don't think I have any stainless tubing left. We built many bumpers for Fontaine trailer company a couple years ago so I'm definitely used to working with stainless...... it just depends on whether or not I have any stainless or how much it would cost me to get some.

It should be okay like it is but I'll update you once I get the lights on there. The way I designed the mounting arm will help with strength/stability and I can tell you it's most definitely strong. I can rock the truck side/side and up/down just by grabbing the bar and it doesn't even budge. If I jerk on it with all my strength I can slightly move it but nothing extreme...... I'm talking about a 1/16" or so at the most.

 

very nice fab skills sir. and nice truck overall

ROLL TIDE :P

 

Thanks!

I can't agree with the roll tide though.

 

Good Job!! Looks Awesome!! I have a lower billet grill do think there would be anyway to fab something so that I could still use a light bar? Thanks

 

I don't think so. If you want to keep the lower billet grille your best option is probably a bull bar.

Just an update...... my lights will be here tomorrow and I should be able to get them on sometime this week. Pics soon!

 

Man, that light bar is looking good!

 

Thanks!

 

Funny i mentioned wanting one when i bought a truck. Now I buy a truck identical to yours haha

-Curtis-

 

Looks AWESOME!! Great work.

So when you going to make some more??? HINT HINT

 

The lights are on and so far everything looks great! I haven't wired them yet but I plan to sometime during the next couple days and then I'll get some night shots. I can say the lights seem to be well made and have a really nice wiring harness.