Hey guys, finally got a chance to get started on this. Again I'm looking for it to be more along the lines of a police style push bar.
Heres what I started with, pic of jca21's as I don't have a before.
First up I cut off the headlight guards with a sawzall. The tubing wall is very thin on these, I'd be surprised if it were any more than a 1/16th of an inch thick
I was trying to avoid taking off the rubber that covers the uprights but while cutting the light guards I nicked it with the saw so off they came. These look as though they are pressed or slid along the T from the factory, I tried to slide them off the same way but they wouldn't budge so I pried them over the T with a large screw driver, hopefully I can slide em back on.
Next I used my Dremel (only because the the metal was so thin) and about 6-8 cut off wheels to remove the rest of the tubing down to the weld, sorry no pic
Then using my 4 1/2" grinder I ground down the welds with a metal wheel then used a 120 grit flap disc to smooth them all out nice, again sorry no pics. I was on a roll and couldn't stop

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I ended up sanding both sides of each upright due to the crappy paint job they did at the factory

Then primed and painted
See any grind marks??
And a sideways pick just to show where I'm at.
Tomorrow I'll get a good look at in the sun to see how well the rattle can black matches. If it looks good you'll see some pics of it on the truck here tomorrow night. If it looks like $hit I'm gonna drop it off it the local powder coat guy and have him re-coat the entire thing in matte black. Hmm that makes me think...maybe I'll lust let the powder coater do it in matte...stay tuned!
This thing better look good on my truck or I'm gonna be pissed :lmao: