jmu427

So after deciding that I was going to try out one of the cheap-o 30" LED bars, I figured I needed a mount. While I was at it, I thought I should make a roof rack which would give me places to mount lights on the sides and rear too for good measure, but didn't want something that sat up too high to get hung up on any branches, etc on the trail. I also didn't really have a need to carry anything up there with the exception of my high lift. I set out to create a light platform that I could slap the jack up there and maybe other things if I needed to later on. I picked up some smaller LED bars for the sides and rear (about 8-9" with 6 LEDs) and some 1.5" 16 gauge square tubing. I like working with the square tubing since it is easy to cut and weld and goes with the boxy XJ theme. I also grabbed some JCR gutter mounts since the PO removed the stock rails and mounts from the roof.

I came up with something I thought would work and got to it.

Here is the light bar that started it all:


Smaller side and rear bars:


After I got everything cut, I mocked up the outer frame:


Here is how the lights will be set up with the 30" bar in the front and the smaller ones on the sides and rear. I made "pockets" they will be recessed in to reduce the chance that they may be grabbed on the trail. The face of the lights will be about 1/4" behind the front plane of the tubing:


First mock-up after tacking. I wanted it to be pretty streamlined and sit about 1" above the roof. The blocks underneath are temp spacers:


Front view with just a slight overlap over the windshield:


Side that is slightly inboard of the roof line:


Rear with clearance for the hatch to open:


Added the cross bracing and welded it up. I spaced the bars far enough apart that I could put some mounting bolts in there for the jack:


OOOHHH bed lined:


That's it for now. I am in the process of moving houses so the project has been put on hold for the moment. I just need to mount it up there and run all the wiring and switches to finish up. The gutter mounts worked out better than I thought after I first put them on there. They were loose and flopping around when they were not all tied in with the rack up there, but everything is very sturdy when everything is in place. Questions, comments, suggestions are all appreciated. Thanks.

XJwonders

Nice job

OxfordCherokee2

Are you going to put sidewalls on it? Looks sweet BTW.

Jrozar

If you are going to do flooring, I used a poly chicken coup flooring for my YJ roof rack...

jmu427

Thanks. I don't have any plans right now for rails and sidewalls, but may look at modifications after I actually get it together and get it working.

jmu427

I've never seen that stuff before. I checked it out and kinda like that idea. Thanks for the tip. Has that held up pretty well up there? Have you stacked anything of significant weight up there?

DJKnightmare

The chicken coop flooring idea is interesting. Do you know how much weight it will hold?

LOVE this platform and light idea. I am going to steal this design, if you dont mind. I honestly think this is my favorite design I've seen!

Hardkor

Very nice work. I was just thinking of doing something similar for the same reason. I would like a low profile full length rack to carry misc. stuff on but couldn't find anything I liked design or price range wise. I would rather build it myself anyway. I will keep an eye on this thread.

jmu427

So I finally found the time to finish this thing up in her new home. It is nice to have a indoor place to work on it. All lights are mounted and wired to switch panel that mounted where the radio used to be. All I have is some cell pics right now, sorry. I just need a new windshield after a flop last time out and she will be ready to wheel again.

darklcdfeller

looks awesome! subbing for ideas on mine!

Loggerhead

In for future reference

HS00XJ

Did we ever see this thing lit up?

jmu427

I don't have any pics, but did get it fired up in the shop one night. It was like daylight in there. The side and rear lights can pivot up and down to throw light where I may need it. The beams only get cut off from the roof line a few feet away from the rig. I also put each side on a separate switch so I don't blind everybody all at once. I just need to get out on the trails at night and actually use it.

welderman1969

Nice job I really like that design ! By the way where did you get the lights from and price please . Also where did you get the gutter mounts ?
Thanks Brad

jmu427

Thanks. I got the lights off of ebay, nothing special. I think the 30" was around $80 and the smaller pods were $12 each. The gutter mounts are from JCR and they were $50 for all four.