EDIT: The ORIGINAL diy is now in post #17.
After getting feedback from members, visiting a few suggested links, and adding in some of my own new ideas I completely changed the bar and it still costs less than $20.
(all bought at Home Depot)
1 - 3' long x 1 1/4" wide steel bar $4.50
1 - 3' long x 3/4" square aluminum tube $10.50
1 - can of spray paint $3.00
2 - 1 3/4" u bolt $1.00
Total - $19.00
This is a simple project that only requires simple tools. I have already written the DIY steps for my old light bar (moved to post #17) so I am not going into any depth on this one. I will let the pictures do the talking since this thread is pretty much meant to be used for ideas (but my idea is the BEST
because it is 100% rocksolid, cheap, light, and doesn't require a welder).
Then just paint the aluminum tube and bolt it all together. DONE!