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EZ poop pipe ZJ lightbar

Old 03-17-2014, 03:55 PM
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Default 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.
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Old 03-17-2014, 03:57 PM
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Tacked all the tabs up,,,,,
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Old 03-17-2014, 04:02 PM
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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.
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Old 03-17-2014, 04:05 PM
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The grill is a tight fit with the 1/4" bar, but it fits.
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Old 03-17-2014, 04:10 PM
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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.
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Old 03-17-2014, 04:20 PM
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The plugs turned out to be a perfect fit!
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Old 03-17-2014, 04:24 PM
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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.
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Old 03-17-2014, 04:31 PM
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and it's done. Total time maybe 3 hours including drying time.
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Old 04-14-2014, 01:30 PM
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Hope you have some EXTREMELY slim/low profile lights or you are going to have to modify the grille.
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Old 04-22-2014, 09:32 PM
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[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.
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Old 04-22-2014, 09:44 PM
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Here's a front shot of the mounted LED light bar. The output is quite impressive
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Old 04-27-2014, 07:18 PM
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That looks pretty good
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Old 04-27-2014, 09:12 PM
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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
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Old 04-28-2014, 05:41 PM
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Originally Posted by outlawcherokee View Post
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
The same was said of my interior and roof racks. I chose the "poop pipe" identifier as a common reference to my other builds when doing a search.

Thanks for the complements!
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