Baja inspired light bar
Thread Starter
CF Veteran




Joined: Jun 2009
Posts: 2,609
Likes: 446
From: Michigan
Year: 1987 MJ, 1973 J2000, 1986 XJ, 08 JK
Model: Comanche (MJ)
Engine: 4.0L H.O
nope only on the front.... the reason for the length of the side bars is for strength and support... by the end of this Fab project you will understand
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so i managed to get some welding time in on it today along side working on my Comanche.... but after welding this cross bar in place and then mocking it up on the XJ i find out i should've checked for clearance before deciding where to put it..... go figure... as it sits now the very center of the cross bar makes contact with the roof itself..... might get a pic tomorrow..... so now i gotta cut it off and reposition it about 1.5" or so forward SOAB!!!!!!! i had figured all my measurements on where to mount the light tabs and where to drill holes...
so a little set back but i may have it corrected by this weekend
--------------------------------------------------------------------------


so i managed to get some welding time in on it today along side working on my Comanche.... but after welding this cross bar in place and then mocking it up on the XJ i find out i should've checked for clearance before deciding where to put it..... go figure... as it sits now the very center of the cross bar makes contact with the roof itself..... might get a pic tomorrow..... so now i gotta cut it off and reposition it about 1.5" or so forward SOAB!!!!!!! i had figured all my measurements on where to mount the light tabs and where to drill holes...
so a little set back but i may have it corrected by this weekend
Thread Starter
CF Veteran




Joined: Jun 2009
Posts: 2,609
Likes: 446
From: Michigan
Year: 1987 MJ, 1973 J2000, 1986 XJ, 08 JK
Model: Comanche (MJ)
Engine: 4.0L H.O
Thread Starter
CF Veteran




Joined: Jun 2009
Posts: 2,609
Likes: 446
From: Michigan
Year: 1987 MJ, 1973 J2000, 1986 XJ, 08 JK
Model: Comanche (MJ)
Engine: 4.0L H.O
Thread Starter
CF Veteran




Joined: Jun 2009
Posts: 2,609
Likes: 446
From: Michigan
Year: 1987 MJ, 1973 J2000, 1986 XJ, 08 JK
Model: Comanche (MJ)
Engine: 4.0L H.O

so far in the fab i have (3) 10ft 3/4" I.D. Galvanized conduit ($10 ea.) the brackets from JCR ($46 shipped) and the bender ($76) so thats a total of $152...... not too bad
thanks for all the comments, really enjoying this fab project
Senior Member
Joined: Mar 2011
Posts: 693
Likes: 0
From: Lexington Park, MD
Year: 2000
Model: Cherokee
Engine: 4.0L I6
yea they seem pretty moderate until you actually stack em up and "mounted" em... as for drive-through's. Yes i should be ok... my overall height with the rack mount, to my highest point will be around 6.5ft.... average drive through is 8ft minimum... i dont really plan on hitting any tight trails so i'm not concerned with having it ripped off.. 
lol plz do, and be sure throw some pictures up here. Its nice to know my fab project has inspired someone to make their own. I thought about making it a slim style low-profile rack but my xj has a sunroof.... so its not too practical... the bender, i picked up from Menards...
so far in the fab i have (3) 10ft 3/4" I.D. Galvanized conduit ($10 ea.) the brackets from JCR ($46 shipped) and the bender ($76) so thats a total of $152...... not too bad
thanks for all the comments, really enjoying this fab project

lol plz do, and be sure throw some pictures up here. Its nice to know my fab project has inspired someone to make their own. I thought about making it a slim style low-profile rack but my xj has a sunroof.... so its not too practical... the bender, i picked up from Menards...
so far in the fab i have (3) 10ft 3/4" I.D. Galvanized conduit ($10 ea.) the brackets from JCR ($46 shipped) and the bender ($76) so thats a total of $152...... not too bad
thanks for all the comments, really enjoying this fab project
Thread Starter
CF Veteran




Joined: Jun 2009
Posts: 2,609
Likes: 446
From: Michigan
Year: 1987 MJ, 1973 J2000, 1986 XJ, 08 JK
Model: Comanche (MJ)
Engine: 4.0L H.O
thx again guys,
yea i figured when i posted where i picked the bender up from i prolly should have posted (any basic home improvement super center). (BTW yea i know where newaygo is, ever been out to Baptist Lake??)
Unfortunately though when i really got moving on this project this passed friday afternoon when i got home from work..... I drastically underestimated the
DANGERS
of welding galvanized without a filtered Mask
.... No, a plain bandana will not suffice
.... "my stupidity" so i have been sick as a dog with Galvanized Poisoning since....(basically gives you a hardcore flu sickness) 3 -days now, nothing but hot soup n tea and not leaving the bed.
I hope to have this finished this week, after i pickup some sweet face masks
Only have about 5 more pieces to weld on so it wont take much
SO PLZ everyone wear proper Venting and filtering masks when welding galvanized anything.....
yea i figured when i posted where i picked the bender up from i prolly should have posted (any basic home improvement super center). (BTW yea i know where newaygo is, ever been out to Baptist Lake??)
Unfortunately though when i really got moving on this project this passed friday afternoon when i got home from work..... I drastically underestimated the
DANGERS
of welding galvanized without a filtered Mask
.... No, a plain bandana will not suffice
.... "my stupidity" so i have been sick as a dog with Galvanized Poisoning since....(basically gives you a hardcore flu sickness) 3 -days now, nothing but hot soup n tea and not leaving the bed.I hope to have this finished this week, after i pickup some sweet face masks
SO PLZ everyone wear proper Venting and filtering masks when welding galvanized anything.....
Senior Member
Joined: Mar 2011
Posts: 693
Likes: 0
From: Lexington Park, MD
Year: 2000
Model: Cherokee
Engine: 4.0L I6
thx again guys,
yea i figured when i posted where i picked the bender up from i prolly should have posted (any basic home improvement super center). (BTW yea i know where newaygo is, ever been out to Baptist Lake??)
Unfortunately though when i really got moving on this project this passed friday afternoon when i got home from work..... I drastically underestimated the
DANGERS
of welding galvanized without a filtered Mask
.... No, a plain bandana will not suffice
.... "my stupidity" so i have been sick as a dog with Galvanized Poisoning since....(basically gives you a hardcore flu sickness) 3 -days now, nothing but hot soup n tea and not leaving the bed.
I hope to have this finished this week, after i pickup some sweet face masks
Only have about 5 more pieces to weld on so it wont take much
SO PLZ everyone wear proper Venting and filtering masks when welding galvanized anything.....
yea i figured when i posted where i picked the bender up from i prolly should have posted (any basic home improvement super center). (BTW yea i know where newaygo is, ever been out to Baptist Lake??)
Unfortunately though when i really got moving on this project this passed friday afternoon when i got home from work..... I drastically underestimated the
DANGERS
of welding galvanized without a filtered Mask
.... No, a plain bandana will not suffice
.... "my stupidity" so i have been sick as a dog with Galvanized Poisoning since....(basically gives you a hardcore flu sickness) 3 -days now, nothing but hot soup n tea and not leaving the bed.I hope to have this finished this week, after i pickup some sweet face masks
SO PLZ everyone wear proper Venting and filtering masks when welding galvanized anything.....













