Roof mount light bar with homemade roof mounting angles

[toothpaste22]

Hi all,

Previously I posted and asked if any manufacturer has come up with a solution just to use the mounting holes for light bar mounting brackets, and couldnt really find one. Most people recommended mounting light bars to roof rack, which is the traditional approach.

I measured and came up with some simple design. Got some 1/4” aluminum 90degree angles, cut, filed, and drilled mounting holes.

Here are some measurements. Roof mounting hole thread is M6-1.0 , it depth/bottoms out (without any mount) is about 17mm. Roof channel width is 1-1/4”, the holes are centered and 2-1/8” apart.

For my set up (you should measure yours prior to making them), roof mounting angle was raised 3-1/4” , side angle is 2-1/8” to provide mounting holes for my light bar mounting style.
The whole set up is pretty solid, cleared the roof about 3/8”. Yes, wind noise increased, i’ll see if wrapping some paracord would help.

So yea, I thought it’s pretty cool and share. Let me know what yall think.

Have a wonderful weekend!

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[kansaswill]

Any wind noise?

Edit: I can't read. Lol.

 

[DaveTaco17]

The Diode Dynamics Kuat DEK rack integrates into the roof holes. Gives you an Stage series light bar and roof rack. It does add some drag at higher speeds, as expected, but zero whistling and acts as a portable sun when you need it. Took me about two hours to get everything where I wanted.

 

[Will721]

Its a creative solution. If it were me, now that you have everything fitting exactly like you want, I'd pull it all off and start trimming and shaping it. Trace around that light bars foot and cut it all out. Then add a nice angle cut on the top of the angle iron thats parallel to the door. Then just round all the edges. Using a bed liner spray with some texture hides any imperfections and seals the metal from corrosion.


The only difference between a home made solution and a production product is the details. The more time you spend shaping and cleaning it up the more professional the end appearance will be. Plus, minimizing front facing flat surfaces and rounding edges will cut wind noise.

 

[toothpaste22]

The Diode Dynamics Kuat DEK rack integrates into the roof holes. Gives you an Stage series light bar and roof rack. It does add some drag at higher speeds, as expected, but zero whistling and acts as a portable sun when you need it. Took me about two hours to get everything where I wanted.

i just looked it up, it is quite expensive!

 

[toothpaste22]

Its a creative solution. If it were me, now that you have everything fitting exactly like you want, I'd pull it all off and start trimming and shaping it. Trace around that light bars foot and cut it all out. Then add a nice angle cut on the top of the angle iron thats parallel to the door. Then just round all the edges. Using a bed liner spray with some texture hides any imperfections and seals the metal from corrosion.


The only difference between a home made solution and a production product is the details. The more time you spend shaping and cleaning it up the more professional the end appearance will be. Plus, minimizing front facing flat surfaces and rounding edges will cut wind noise.

Oh definitely! I still got some more aluminum angles to mess around with. As you can tell, there’s imperfection such as the lightbar foots are slightly extend beyond the mounting bracket. And there are “second”holes on the mounting brackets as well… those were too low.
But yea, your points make perfect sense, I’ll probably make another set in the near future

 

[Rubenc87]

Nice job. Looks good

 

[MandRautomotive]

Hi all,

Previously I posted and asked if any manufacturer has come up with a solution just to use the mounting holes for light bar mounting brackets, and couldnt really find one. Most people recommended mounting light bars to roof rack, which is the traditional approach.

I measured and came up with some simple design. Got some 1/4” aluminum 90degree angles, cut, filed, and drilled mounting holes.

Here are some measurements. Roof mounting hole thread is M6-1.0 , it depth/bottoms out (without any mount) is about 17mm. Roof channel width is 1-1/4”, the holes are centered and 2-1/8” apart.

For my set up (you should measure yours prior to making them), roof mounting angle was raised 3-1/4” , side angle is 2-1/8” to provide mounting holes for my light bar mounting style.
The whole set up is pretty solid, cleared the roof about 3/8”. Yes, wind noise increased, i’ll see if wrapping some paracord would help.

So yea, I thought it’s pretty cool and share. Let me know what yall think.

Have a wonderful weekend!

Nice job!

Sponsored