EZ poop pipe ZJ lightbar

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Mar 17, 2014 | 03:55 PM
  #1  
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.

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 03:57 PM
  #2  
Tacked all the tabs up,,,,,

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:02 PM
  #3  
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.

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:05 PM
  #4  
The grill is a tight fit with the 1/4" bar, but it fits.

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:10 PM
  #5  
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.

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:20 PM
  #6  
The plugs turned out to be a perfect fit!

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:24 PM
  #7  
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.

EZ poop pipe ZJ lightbar-image.jpg  

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Mar 17, 2014 | 04:31 PM
  #8  
and it's done. Total time maybe 3 hours including drying time.

EZ poop pipe ZJ lightbar-image.jpg  

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Apr 14, 2014 | 01:30 PM
  #9  
Hope you have some EXTREMELY slim/low profile lights or you are going to have to modify the grille.
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Apr 22, 2014 | 09:32 PM
  #10  
[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.

EZ poop pipe ZJ lightbar-image.jpg  

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Apr 22, 2014 | 09:44 PM
  #11  
Here's a front shot of the mounted LED light bar. The output is quite impressive

EZ poop pipe ZJ lightbar-image.jpg  

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Apr 27, 2014 | 07:18 PM
  #12  
That looks pretty good
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Apr 27, 2014 | 09:12 PM
  #13  
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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Apr 28, 2014 | 05:41 PM
  #14  
Quote: 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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