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Thread: Custom jk bumper mount grill guard and light bar

  1. #1
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    Custom jk bumper mount grill guard and light bar

    I finally finished the light bar for the front of my 2012 sahara. The criteria i wanted to meet when i started out was a) it should hug the grill without rubbing, b) I needed to mount it without loosing or notching the stock bumper or the plastic cowling that sits over the brake pump, and c) I wanted a finish on it that almost resembles that of the flat black plastic of the bumpers, mirrors, etc.

    A) after some tearing apart and figuring out a mounting position, if found the holes for the plastic cowling on the top between the bumper and grill as the ideal location to bolt it on and the largest pipe i could fit in there was 1 1/2 inch. next i measured a few times and came to the conclusion that 62" of pipe with bends at 17" in from both ends would fit.
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    The finish i chose for it was Rustoleum plasti-dip. After sanding, and cleaning with thinners i applied a coat of primer, then lightly sanded with 400 grit and then I started spraying on the plasti-dip. For future endeavors I would suggest waiting a minimum of 24 hours before starting with the plasti-dip. The primer bled through the first 2 coats of it and it ended up taking 6 coats to get the finish I was looking for. It was still only the 2 cans i bought, this stuff actually covers pretty well.

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    Now the main theme behind this little build of mine was budget! The steel was out of the scrap at work, the lights are a princess auto special at 34.99 for 2 lights, wiring, inline fuse, and the switch, and the rustoleum ran me 2 cans at 14.99 each. So for 65 bucks plus tax I have completed my first custom build project for my own vehicle. (it's my first jeep) I would love to hear your comments on this build as i am very happy with how it came out.
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  2. #2
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    Looks good man, is it difficult to remove for when needing to remove the grill to work on stuff? that would be my only concern if its hugging the grill!

    great first project though
    2012 JKU Sahara, SD HP60 Front, GM 14 Bolt shaved rear, 5.38s, locked/Spooled, 4 link front 3 link rear, Oris, TR Double Beadlocks, 42" tsl sx2, PSC Full Hydro, D3 bumpers, D3 skids, D3 Rock Rails, D3 Cage, and lots more...
    OF4WD #5252

  3. #3
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    Need to get your hands on a tube bender. Or a poor mans bender sand and an oil drum.

    Sent from my SGH-I337M using Tapatalk

  4. #4
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    Quote Originally Posted by just_in View Post
    Need to get your hands on a tube bender. Or a poor mans bender sand and an oil drum.

    Sent from my SGH-I337M using Tapatalk
    i will admit it would have been easier with a tube bender, however, the tin i welded over the corners is barely noticeable from up close and pretty well invisible from a distance.

  5. #5
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    Quote Originally Posted by just-lift-it View Post
    Looks good man, is it difficult to remove for when needing to remove the grill to work on stuff? that would be my only concern if its hugging the grill!

    great first project though
    it's a five minute removal, i reamed out the holes where the plastic clips were for the cowling and tacked in 3/8 flange nuts so that the light bar is a 1 wrench job plus the wiring harness that is zip tied behind the grill. the tricky part of it is sliding it out without marking the bumper or grill but it is doable just a little tricky!

  6. #6
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    it finally has something on it to make it look different from all the soccer moms driving them here in wasaga

  7. #7
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    scratches add character though! haha

  8. #8
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    well you got the jeep bug...... you will never be finished


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    a learning experience is one of those things that says, you know that thing you just did...don't do that again.

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