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Old 05-28-2011, 08:51 AM   #5176
573
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Here's my new setup. How it works is the bottom part stays on the car and the top part with the lights is held to the bottom part with two bolts so it's easy to remove. I still have to stop at Terminal Supply and pick up a big 4 pin connector for all the lights. The lights don't shake at all on paved roads or on ordinary dirt roads. While hauling ass down rutted trails they shake a bit, but the output is still plenty useful. I wanted something solid, good looking, and easy to remove since I don't always need lights. This bar definitely fills those criteria so I'm happy.









For those who don't know my previous setups, this goes between the bumper beam and the license plate holes. It adds a ton of rigidity and I can stand on it.
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Old 05-28-2011, 02:53 PM   #5177
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Do you have any measurements for that last piece? That was going to be my next addition, as soon as I can get the time to weld one up. Why does it look angled down in the picture? It could just be the photo angle. Looks sturdy otherwise
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Old 05-28-2011, 04:03 PM   #5178
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Quote:
Originally Posted by Superorb View Post
2pt5RSdan

^^ Looks good, have any pics of the mounting and without the lamps mounted?
I made these brackets to hold two lights with the thought that I'd throw a crossbar on and add two more eventually. The brackets are 1/4 inch steel flat stock that just bent and drilled. Not the lightest in the world, but they don't wobble at all.





When I got the second set of lights, I just got an angle bar, cut to length, drilled 6 holes (four for lights, two for mounts). Two bolts hold the bar to the brackets, and I wired the lights in using a 4 plug trailer wiring harness, the the whole bar is quick disconnect with just two 17mm wrenches, which I like for when I park in the city or do long highway trips and don't want the attention.

I'll try and get some pics of the setup up close, but my phone camera sucks and it's pretty easy to remake with just what I described above.


Quote:
Originally Posted by tommyson01 View Post
Quote:
Originally Posted by 2point5RS_Dan View Post

Which lights did you pick up and do you have any down range shots?
Inners are 500FFs and outers are older 500s. I got the lights for dirt cheap locally. It's an okay setup, good enough for what I do.
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Old 05-30-2011, 07:15 PM   #5179
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Quote:
Originally Posted by premier00000 View Post
Just noticed my Rally Innovations light bar is starting to rust pretty bad where the welds are... Any one have any ideas on what I can do?

Thought about covering the whole bar in undercoat, or bedliner. Just wondering what other options I'd have.

(And I've only had it since mid august.)
ive had mine for a few months now and it's staring to rust on the inside, where they didn't cap off they bar like they should have so water could collect if left outside.... for $260 you think they would have

and a little whoring
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Old 05-30-2011, 07:25 PM   #5180
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Quote:
Originally Posted by subiidude

ive had mine for a few months now and it's staring to rust on the inside, where they didn't cap off they bar like they should have so water could collect if left outside.... for $260 you think they would have

and a little whoring
My thoughts exactly, should have had a local speed shop make me a better bar that is more secure, and better quality for less than half the price.


I'm gonna hit the entire bar with a heat gun to make sure there's no moisture in it and then spray the inside with foam, and outside with primer and undercoat... Or have it re-engineered altogether.
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Old 05-30-2011, 07:30 PM   #5181
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Originally Posted by subiidude View Post
ive had mine for a few months now and it's staring to rust on the inside, where they didn't cap off they bar like they should have so water could collect if left outside.... for $260 you think they would have
Dang. That looks pretty clean subiidude. Maybe you should have gone with the oswald bumper beam $240 shipped and you get to save a bunch of weight.

Anyway. Some people were asking about what the light throw really looked like on the Hella 500's. (plus I got a flat tire on a drive and time to take pictures. Sorry for the craptastic phone camera)

Low beams


Lows highs and 500's pointed to the sides of the highs as fill


Lows and 500's (no highs, for reference)


Lows, highs and 500's pointed straight
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Old 05-30-2011, 07:54 PM   #5182
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Quote:
Originally Posted by premier00000 View Post
Just noticed my Rally Innovations light bar is starting to rust pretty bad where the welds are... Any one have any ideas on what I can do?

Thought about covering the whole bar in undercoat, or bedliner. Just wondering what other options I'd have.

(And I've only had it since mid august.)

Mine is rusting in spots as well. With it being up front taking on road debris coupled with harsh salty mid-west winters, I knew it was just a matter of time. I'll probably sand it down and put some Rust Bullet on it. I'm not sure what I'll cover that with though.
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Old 06-01-2011, 05:42 PM   #5183
DUSTIN 217 WRX
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I Like the rides guys!
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Old 06-01-2011, 07:36 PM   #5184
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Quote:
Originally Posted by ag04 View Post
Do you have any measurements for that last piece? That was going to be my next addition, as soon as I can get the time to weld one up. Why does it look angled down in the picture? It could just be the photo angle. Looks sturdy otherwise


Disregard the 3" measure and cut that to 2.5". I had to hack about half an inch out of it to make the bumper fit properly.

It angled down a bit. That's likely due to me cutting out that half inch of material with a plasma cutter without measuring or making anything. Next time I have it off, I might fix that.
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Old 06-01-2011, 09:37 PM   #5185
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Quote:
Originally Posted by 573 View Post

Disregard the 3" measure and cut that to 2.5". I had to hack about half an inch out of it to make the bumper fit properly.

It angled down a bit. That's likely due to me cutting out that half inch of material with a plasma cutter without measuring or making anything. Next time I have it off, I might fix that.
Care to fab up another one?
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Old 06-01-2011, 09:44 PM   #5186
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Originally Posted by Superorb View Post
Care to fab up another one?
If I had a band saw, welder, and material on hand, I would. Unfortunately, I don't have any of that. I cut this one with a hack saw and had my friend weld it.
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Old 06-01-2011, 10:22 PM   #5187
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Ahh..
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Old 06-02-2011, 01:47 PM   #5188
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just found some Hella 550s in my garage. obviously gonna attempt to install them on my subby. but, i got a couple of questions.

1. how many auxiliary lights can the battery support? i assume the two 550s should be fine.
2. did y'all just use the Hella switch that comes with the lights...
3. OR did you get your hands on a factory switch?

i have more questions but can't think of them right now. thanks in advance.
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Old 06-02-2011, 01:57 PM   #5189
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Quote:
Originally Posted by KangaRu99
just found some Hella 550s in my garage. obviously gonna attempt to install them on my subby. but, i got a couple of questions.

1. how many auxiliary lights can the battery support? i assume the two 550s should be fine.
2. did y'all just use the Hella switch that comes with the lights...
3. OR did you get your hands on a factory switch?

i have more questions but can't think of them right now. thanks in advance.
The lights and all other electrical components get their power from the alternator when you're driving. Pretty much all the battery does is start the car, and makes voltage spikes less harsh.

I used the Hella switch, I mounted it on the fuse panel cover.
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Old 06-02-2011, 04:02 PM   #5190
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So two 550s will work fine?
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Old 06-02-2011, 04:08 PM   #5191
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I'm sure 4 or 6 are fine.
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Old 06-02-2011, 04:21 PM   #5192
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Quote:
Originally Posted by premier00000 View Post
I'm sure 4 or 6 are fine.
thats what i assumed. my alternators rated for like 75amp. i dont know how much the two 550s are pulling, but i think even with nighttime driving systems, i feel like it'll be fine
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Old 06-02-2011, 04:47 PM   #5193
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Four is pushing it, especially when you consider you're likely using high beams along with four lamps. That's 25A for the 6 lamps alone, not to mention any other systems that require power.Also keep in mind that the alternator may be rated for 75A, but those 75A are not delivered at idle, usually around 3000rpm+. Six lamps + high beams is roughly 33A, and if your car also runs the low beams when the highs are on that's another 8A draw.
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Old 06-27-2011, 02:10 PM   #5194
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My $25 light bar. The actual lights were the expensive part.




Ignore the wiring, I still needed to buy some longer zip ties at that point.
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Old 06-27-2011, 04:22 PM   #5195
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^^ Did you fab that up yourself?
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Old 06-27-2011, 06:17 PM   #5196
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yeah, he took his sweet time on it too
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Old 06-27-2011, 09:45 PM   #5197
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Originally Posted by 02boxer View Post
yeah, he took his sweet time on it too
'Tis true. I started it last year with the hopes of having it finished before LSPR (mid-October). When I realized that wasn't going to happen I just let it sit for the winter and dusted if off in the spring.

Basically it's a display of "what you can do with a harbor freight welder and tube bender." I think it's pretty obvious the inspiration of the overall design was inspired by the rally innovations bar, but with a few tweaks. I bumped the tube OD and wall thickness up from the RI's 1.25" and 0.050" to 1.5" and 0.065". I thought the larger tube looked a little more proportionate on the car. Secondly, the main mount is a receiver-style on the two top tubes you see going into the lower grill area (going to a couple brackets I made that attached to the bumper beam at three points). There are also two arms on the bottom that attach underneath.

The thing is absolutely rock solid. Now I just need to get out on some back roads to enjoy the simulated sunlight those 4000's put out!
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Old 06-28-2011, 03:48 AM   #5198
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Quote:
Originally Posted by Adventure Dave View Post
My turn!

I didn't want the slightly heavier/ more expensive Rally Innovations light bar. But I did want the Oswald performance bumper beam. Why not combine the two?


Added extra "tow hook" bosses



Simple barstock bracket.


/he hella's wire to come on with the fog light switch which was silly


Wired to come on with the high beams, MUCH better.
brilliant idea.....killing two birds with one stone.
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Old 07-02-2011, 05:39 PM   #5199
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finally mounted up my 550s.

piece of pipe in my garage = $0
legs from an old lamp beat into shape = $0
can of paint i already had = $0
various nuts/bolts = $0

Not the cleanest or perfectly level light bar, but it's rigid and will do its job wonderfully. I'd say I'm happy with zero dollars spent and about two hours of work.



IMG-20110702-00434 by Fnavazio, on Flickr

IMG-20110702-00431 by Fnavazio, on Flickr


(the two legs are mounted under the grill into the bumper, then the pipe was welded to the legs to form 1 piece. the lights are then mounted thru the pipe)
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Old 07-02-2011, 10:46 PM   #5200
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simple and effective is the name of the game!
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