11-12-2015, 10:00 PM | #1 |
Join Date: Jun 2012
Posts: 220
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Denali LED Lightbar Installation
I have some custom mounted LED fogs which I have another thread on (you can see them in the pictures). I like them so much i decided to add a lightbar but I didnt want it to be very noticeable. I selected the location of the lower grill and decided to do a non-welded installation so anyone at home with simple hand tools could copy.
Here's the grill area in question, the lower plastic piece between the tow hooks. Youll want to slide under the truck and remove the pushpins that hold it in. Here it is on the ground Here is what we are gonna replace it with, a 26" curved bar. Notice they are almost identical in size. To install you will need some flat bar. I chose aluminum but steel would be ok also. You can buy this from Home depot for about $10 per piece. We will only need two small pieces. For simplicity sake I chose a bolt that holds the tow hook to attach our bracket too. No reason to reinvent the wheel when the bolt is very close to the location of the lightbar. We will need to drill a mounting hole. Based on location and angle the brackets need a 90 degree bend or so. Clamp it and just twist it with a pair of pliers. Now they have final bends, cut to size, and a hole drill to mount the light to. Here is an underside view: Reattach the stock bolts, your brackets, and your new lightbar
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06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF 95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2" 04 XR80 - Stock 07 CRF50 - Stock |
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11-12-2015, 10:19 PM | #2 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Thanks for sharing the nice project. Where did you purchase the light bar?
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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11-12-2015, 11:00 PM | #4 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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What an excellent job. A lot of people are going to appreciate the work that you put into the pictures in that thread. I'm sure other people will replicate your project.
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11-13-2015, 12:49 AM | #5 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Indeed, I know from personal experience, it takes time, and effort, to document your work so well with photographs. Thanks for caring enough to detail the fabrication of your project with such excellent photos.
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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11-13-2015, 10:32 AM | #6 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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Great job! I love good, clean home fabrication!
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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11-13-2015, 11:39 AM | #7 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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It looks like that light bar was meant to fit in that space! Awesome!
If you anneal the aluminum, it will be much easier to bend and it will resist cracking down the road. All it takes is a bar of soap and a propane torch.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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11-13-2015, 01:59 PM | #8 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
How much heat is necessary? What is the purpose of the soap? Please do elaborate.
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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11-13-2015, 04:37 PM | #9 |
Join Date: May 2007
Location: Altamont, Kansas
Posts: 15,103
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I need one of those on the minivan.
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11-14-2015, 05:16 PM | #10 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Rub the soap on the aluminum, for something similar to a litmus test. Heat it slowly and evenly with the torch until the soap begins to turn black. VoilĂ . It'll bend quite easily without cracking.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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11-14-2015, 05:54 PM | #11 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Thanks for the great tip, Weld.
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Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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11-21-2015, 03:53 PM | #12 |
Join Date: Jun 2012
Posts: 220
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Nice tip......
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06 Foreman 500 - 29.5 OG Outlaws, 35%, Warn 2.5k, HL^2", <2.5">, EPI, HMF 95 Fourtrax 300 - 27" Zillas, SS212s , Viper 3k, HL^2" 04 XR80 - Stock 07 CRF50 - Stock |
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