I know this has been discussed many many times, believe me, I know, I've read them all. lol

But one thing that wasnt covered was the measurements....

I plan on getting 1.5" angle steel and couple of low-profile lights...probably all driving lights.

But I wanted to ask what the measurements are....like length of the bar...how much do I saw off at both ends? How far between both ends for the roof rail mounts?

Any ideas of best tool to saw with? I dont have a saw-zall...are they expensive?

But I wanted to ask what the measurements are....like length of the bar...how much do I saw off at both ends? How far between both ends for the roof rail mounts?

Man... i totally had all of the measurements i used typed up in a word document... but i can't find it :(

Any ideas of best tool to saw with? I dont have a saw-zall...are they expensive?

i just used a small hacksaw to cut mine and a metal file to take off the burs

Why don't you just grab a tape measure and measure your roof rack...

A sawzall is not necessary for 1 1/2 angle iron just get a hacksaw take some measurements and start cutting.

Personally I would use a grinder with a metal wheel it would be so much faster but more difficult unless your good with a grinder

i made one but never put it on cause i didnt like it but i just used a hack saw. mine already had the holes in it so i didnt have to worry about that but just measure from center to center

Why don't you just grab a tape measure and measure your roof rack...

A sawzall is not necessary for 1 1/2 angle iron just get a hacksaw take some measurements and start cutting.

Personally I would use a grinder with a metal wheel it would be so much faster but more difficult unless your good with a grinder

Cuz it would save me alot of time and would be easier to do it without spending some time measuring and double-measuring if somebody had a existing measurements.....

on my 02 i used a 3" wide by 3/8" bar and i cut it to 38" i used a saw at work and i dont remeber the demensions i used for the holes i have my blue print somewhere ill draw it in paint after work

the holes were 3/8 from the corners. and the only thing you will need to do is get new bolts fro the top of the front fairing and washers i used the hook bolts for the back holes

picture of the bolts and the stock loop bolt
http://i51.photobucket.com/albums/f354/demonwolf19/Picture047.jpg

all 4 of my lights
http://i51.photobucket.com/albums/f354/demonwolf19/Picture048.jpg

i cut out 1 1/4" holes for the rubber bushings that came with my lights.
http://i51.photobucket.com/albums/f354/demonwolf19/Picture049.jpg

oh i used a coat of primer then a flat black finish

Very nicely done, Buckethead!

Thanks!

I know this is pretty obvious question but what do you think about this setup-

2 fogs on the outside while 2 driving lights inside

Or

4 driving lights?

i would go with the driving lights as they are brighter and if your doing trail runs it helps come sun down.

hey man i have a piece of angle iron that would be perfect for you light bar. i also have a light bar that i made but didnt like it if you want you i will bring them to mod day

That'd be cool...do you care to show a pic of that lightbar you fabbed up? I probably will take the angle iron though.

yea let me see if i can get a good pic real quick give me ten mins

ok man here you go it needs to be sanded down and painted but other then that its good to go!
http://i86.photobucket.com/albums/k114/elko1743/IMG_0187.jpg http://i86.photobucket.com/albums/k114/elko1743/IMG_0188.jpghttp://i86.photobucket.com/albums/k114/elko1743/IMG_0189.jpg

Not bad for your fabwork!

Bring them both to mod day or maybe sometime before then, I could drop by and look at them and take one of them and work on it some and do the wiring over at Tuffs.

ok umm just text me somtime this weekend me and whit are planning of going to greek fest were you going to go ?if so we could just meet up there and i will bring both of them for you or we could meet up anytime this weekend

is that your room justin?
beer bottle on the wall. fishy sheets. tupperware w/ old food on the bed that is not made up.
youre how old?

:)

hahah i sleep with the fish... no use to have an apartment but then i started dating whit and helping her raise hunter ( who i call my son ) and it was just more financially suitable for me to move back in with my grandparents so i could start paying stuff off so me and whit can get a house. but i just finished that food about 15 mins ago so GET OFF ME MOM!!! lol

thats awesome man, that makes sense, but i still find it kinda funny(the sheets). but hey, you gotta do what you gotta do. yea, i dont believe you finished that food recently.

MAKE UP YOUR BED JUSTIN! HOW MANY TIMES DO I HAVE TO TELL YOU! AND GET YOUR FOOD OUT OF YOUR BED!

Calm down children! Or I'm gonna hafta smack y'all with that hefty pillow of mine if y'all kiddies keep this shit up! LOL

ok umm just text me somtime this weekend me and whit are planning of going to greek fest were you going to go ?if so we could just meet up there and i will bring both of them for you or we could meet up anytime this weekend

I'm not attending the Greek fest but I'll text you this weekend and see which time will work. Where's the greek fest at?

Ok guys,

Another question about the angle iron....

I was at Lowes today and saw this but wanted to ask.

1/8" x 1/2" x 4'

or

1/8" x 2" x 4'

Which do you guys prefer? I liked the 2" because it seemed longer and would be more stable for the lights? Those are in steel though cuz aluminum was like twice the cost of steel so forget that one. Price for those two steel angles wasnt that much different...about a dollar difference.

Do you think 4' is too long? Should I try to go for 3' long bar?

Also, do you guys prefer 1/8" or 3/16"? I think 1/8" is better and wouldnt kill the drill bit....

What do you guys think? I would like to know your opinions before tomorrow night if possible.

bump

would like to know your opinions on those angle iron bar dimensions....before tomorrow night cuz I more likely will get it after work....

measure the width of the rack then use that to figure the length of the bar.... i would go with the 1/8 steel cause the other is overkill for the application at hand.....

the roof rack is about 4 feet wide

so go with the 4' bar cause the 3' wont make it.... LOL

Aight guys, today was my day off so I spent all morning working on the lightbar and well, I dont think I've ever spent so much time with a hacksaw...it felt like tryin' to escape from prison with a hacksaw....lol and had some interesting moments with the drill....NEVER ever lay a drill on your lap while wearing gym shorts....they seem to have an attraction for each other.....

Here's the final results:

http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0756.jpg
http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0757.jpg
http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0758.jpg
http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0759.jpg
http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0760.jpg
http://i298.photobucket.com/albums/mm247/samonett21/xterra/100_0762.jpg

I'm waiting for my Hella FF75's to come in first before I drill the mounting holes on there.

Just noticed that its already been like 7 hrs since I finished it and I'm seeing rust spots already....gonna take it off til I get those mounting holes done then paint it!

if that was my rig i would move it to the closest possible point towards the front....

Are you worried about it shining into the sun roof at night?

if that was my rig i would move it to the closest possible point towards the front....

I have thought about that...will figure it out once I get the wiring done. Would the lights beams bounce off the hood if I had it back there? I plan on having it far above where the high beams lights ends....

Are you worried about it shining into the sun roof at night?

Yeah, I've wondered about that but I've been looking for a sun roof cover and had no luck finding a used one....hate the idea of having to buy one from the dealership though. I will test it out and see what happens with my sunroof if I have it back there after its wired up....look at this way, I could move it back there when I know I'm not gonna use it much....and when I am...just move it up there....I'll still have enough slack in the wiring to do both locations.....

i guarantee it will shine in the moon roof... how do i know cause the ones i have all the way up by the air dam and its still pretty bright.... how much do the shades go for???? i have one that i havent used since i bought the X....

I kinda figured it would brighten up the interior with the sunroof, lol.

Hopefully with the shade, I wont have that issue.....

you are right but i bet you wont leave that shade on all the time....

you are right but i bet you wont leave that shade on all the time....

maybe not all the time...but in the winter, it would be nice to have one since its so freaking cold because I can feel the cool air coming through the sunroof and the shade would provide somewhat better insulation...

ill tell you right now that that isnt going to work.... all it dose os block the sunlight and thats it... there isnt a seal or anything on it....

At least it'll still block the bright lights from coming in, LOL

that it will do.. LOL i have gotten used to the light... and even with the lights where i have them light up the inside of the X....

OK, just came across this sweet simple mod, on the list! My question, where do y'all run the wiring through?

Look into the "Exterior Mods" then go to "Exterior Lighting" and you will find a bunch of threads about running wires....I plan to do mine kinda similar to Shaun's wiring (Vandebogart).