time to make a light bar. your suggestions welcome

[810moto]

Ok, I have decided to make my own light bar instead of spending a few C-Notes.
I already have my lights mounted on some 1/4" flat stock bent at a 90. I have plenty of room to weld on the current mounting spots. The stock I am running now will have added strength to it as well.
Question now is do I go square or round tubing and what size should I use. I will have 4 lights on it and together don't think they add up but to a few pounds so weight is not an issue.
Any inputs or thoughts or designs you might have floating around would be helpful in me figuring out just how to make this happen for under $60.00...yes, I said 60. It can be done and I am they guy to do it 1st (I hope).
I added 3 pics so you can kind of get an idea of what i am starting with.

 

[810moto]

I have decided to go with cold rolled steel but still not sure about the thickness or dia.
someone on here has to have a good idea about this. come on guys, with all the home made stuff we make, help a brother out.

 

[Clemsonfan15]

What's wrong with your current setup?

I'd love to do that same setup with mine.

 

[borgzman]

1 3/4" diameter

 

[810moto]

clemsonfan...nothings wrong with it as it but i have 2 more lights i bought from a member and want to run all 4 across. the set up i have now was pretty simple to make and materials cost me under 45 bucks and the lights were another 40.

BTW bogzman.... do you know how thick it is?
how are those lights on the tucson working out? I still have not had a chance to put them on the hyundia as of yet but i have everything ready to go when i get off my rump to do it. I built me another box instead.

 

[Clemsonfan15]

Check out momo.75.

Toyota - 4Runner . org Forum - View Profile: momo.75

He has four on his bumper just like you have two. They look awesome.

 

[borgzman]

The defiants are 5/16 in thick.
I think, you also need to consider what will you use as end caps.

I can't wait to see it done.
A light bar can cost $250-$300, and now you're building it for $60. :thumb3:
LOL! those guys from Defiant will scratch their head if they read this thread.. J/K.

 

[810moto]

end caps? im sure i have an idea...maybe get a steel ball, cut it in half then weld it on or i might even have some bar end protectors for my dirtbike laying around i could shove in there.

 

[TNations7]

Ok, I have decided to make my own light bar instead of spending a few C-Notes.
I already have my lights mounted on some 1/4" flat stock bent at a 90. I have plenty of room to weld on the current mounting spots. The stock I am running now will have added strength to it as well.
Question now is do I go square or round tubing and what size should I use. I will have 4 lights on it and together don't think they add up but to a few pounds so weight is not an issue.
Any inputs or thoughts or designs you might have floating around would be helpful in me figuring out just how to make this happen for under $60.00...yes, I said 60. It can be done and I am they guy to do it 1st (I hope).
I added 3 pics so you can kind of get an idea of what i am starting with.

I know this is a couple years old.. But how'd the finish product turn out?