EZ poop pipe ZJ lightbar
 

GF took my Dakota and left me her ZJ and I was looking at the mangled factory fogs. I worked up a design in my head and started with a 3' length of 1" sched 80. I put a couple bends in it to suit my taste and cut the ends at a 45. The tabs are 2" wide flat stock .187" thick that I cut using a shear. Laid it all out on the ratty factory bumper to get an idea where I wanted the tabs. Not sure what lights will go on so I went with five tabs.

Tacked all the tabs up,,,,,

Finshed all the welds and cleaned it up with a flap disc. The brackets will attach to the factory mounting holes. I used 1 1/2" .250" thick bar for the mounts as seen in the background.

The grill is a tight fit with the 1/4" bar, but it fits.

Since I cut the tube ends at a 45 degree angle, the holes needed oval shaped plugs. I use plywood and carboard templates with my plasma cutter. My neighbor, who is a woodworker, suggested drilling the plywood template with a holesaw at a 45. That neat little trick did the job.

The plugs turned out to be a perfect fit!

My buddy stopped by with a better JY bumper just in time for the final fitting. The bumper is a little muddy but it will clean up. Everything is welded up and ready for bedliner and lights.

and it's done. Total time maybe 3 hours including drying time. :cheers:

Hope you have some EXTREMELY slim/low profile lights or you are going to have to modify the grille.

[QUOTE=AZSnake98;2832402]Hope you have some EXTREMELY slim/low profile lights or you are going to have to modify the grille.[/QUOT

I have plenty of room behind the light bar. I made these brackets which move the light up an inch, but there's a few inches clearance regardless.

Here's a front shot of the mounted LED light bar. The output is quite impressive:cool2:

That looks pretty good :thumbup:

I must say I'm a little disappointed I came here expecting to laugh at some horrible black pvc poop pipe contraption and this turned out to be a decent looking item :thumbup:

The same was said of my interior and roof racks.:icon_cheesygrin: I chose the "poop pipe" identifier as a common reference to my other builds when doing a search.

Thanks for the complements!