Fabricated Light Mounts for a DII

[LSUDenver]

I have a concept for a light bar for the front of my 00 DII, but I wanted to see if any of you have fabbed one and if you had any pictures.

I don't think my idea is the only one out there, but the best that I could think of.

Please post up with any other ideas.

Any suggestions to my design are welcomed as well.

 

[EricCo]

D2offrover (Solihull member) has a light bar like this on his D2. You may want to pm him to see where he got it.

 

[CapeCodRovers]

just make sure you isolate the metal screws from the aluminum angle with some nylon bushings.

 

[sven]

Dont use sheetmetal screws, use a nut-n-bolt.

 

[LSUDenver]

I know D2Offrover. His light bar is from Rover's North... $150. I thought if I could build something for much less, than I would go that route.

Yes, I thought I would go with Bolts instead of screws. Just didn't update my schematic.

On isolating the screws, I see lights bolted to brush guards all the time that are bolted to the frame. Why would you need to isolate this aluminium bar? Does it hurt that it would be grounded?

 

[Lucasd2002]

Why would you need to isolate this aluminium bar? Does it hurt that it would be grounded?

Steel and aluminum don't mix (assuming your hdwr is steel) - Galvanic corrosion

 

[LSUDenver]

OK, So the sub bumper behind the plastic, I assume is aluminium, right? The angle that I am planning on using is aluminium, but I was planning on using stainless nuts and bolts. QUESTION: so it is not a power / ground issue, but a steel on aluminium issue? Causes which to do what?

Assume that I would use a through hole bushing to isolate the bolt from the aluminium, right?

 

[LSUDenver]

What a minute... The body is aluminium, but the door hinges are steel. There isn't isolation there.

 

[CapeCodRovers]

There isn't?

 

[sven]

What a minute... The body is aluminium, but the door hinges are steel. There isn't isolation there.

The doorskins are alum, but the door frame is steel. The pillars (inner body structure) is all steel. So the hinges arent touching aluminumiunim.

 

[LSUDenver]

So, would it be wiser to use steel angle rather than aluminium? I probably just would not be doing as much cutting and bending on the ends.

Isn't the sub-bumper aluminium or is it steel?

Would using the less hardened zinc bolts and nuts solve the problem?

 

[maxyedor]

Only thing I'd change is I'd add a tab so that you could use a 3rd bolt about 1.5 inches lower than the other ones to counter the flex from vibration. Otherwise, just build it, if it doesn't look or work right, try something else.

 

[No Pvmt]

Do a search, somneone bought one from a vendor (oem).

 

[I HATE PONIES]

The doorskins are alum, but the door frame is steel. The pillars (inner body structure) is all steel. So the hinges arent touching aluminumiunim.

Doorskins are also steel aren't they? I believe that the fenders and hood are aluminum but the "crash cage" and all of the doors are all steel.

 

[d2offrover]

David,

I've seen D2's without the lightbar and driving lights mounted directly to the bumper. When I was in the UK, most of the D2's I saw had hella 500's or similar size lights mounted directly to the bumper.

Here's a pic with lights mounted directly to the bumper.

 

[RovinNC]

I skipped the whole "bar concept" and drilled two holes through the top of the bumper. Now the plastic piece sits still.

 

[Dallas]

On the d2 I was told the door skins are now steel?

The doorskins are alum, but the door frame is steel. The pillars (inner body structure) is all steel. So the hinges arent touching aluminumiunim.

 

[I HATE PONIES]

I just checked with a magnet and they are in fact steel on a 01 DII. The rear door has an aluminum skin but the other four are all steel.

 

[LSUDenver]

Finishsed Product

I finished the fabircation yesterday and the priming, painting, and install today. Took a midnight run around the neighborhood with my lights on and off to test and stop and adjust. Good thing I am on the HOA Board...!

Check out the finished pics...

 

[LilRascle]

I have seen a few mounted to the bumber. I still like the look of this one.....and so far, I have no complaints....except that I forgot to tighten the side bolts after mounting the lights. When I needed them most, turned them on and they were pointing at God. I thought the Landy was trying to tell me something.

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