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Discussion Starter #1
Well, with the stereo project completed, it is time to start on something else. Several months ago, I purchased an LED light set. It has a 32" light bar and four work light cubes. I needed to fabricate some brackets for them, and thought the attachment points for my roof would be a good place to mount them. I'm going to start with the rear facing light brackets first.

I started with 1" tubular steel from Lowes.
50 Back mounts.  Started with 1x1 inch stock.jpg

After cutting to the length I thought would work. I capped the ends and ground down my welds.
4.2.jpg

After test fitting, I didn't like the angle of the lights. They were already aimed as low as they could be aimed. So I cut a slot...
51 Making a cut to angle the mount.jpg

...and made a bend. I will use some scrap metal to fill in the gaps.
52  Cut a piece to fill the gap.jpg
 

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Discussion Starter #2
This is about how it will look once done and in place.
52.2 Angle it should have when complete.jpg

Let me start by saying that I am NOT a skilled welder. I use a cheap Harbor Freight wire welder, and am learning as I go. You will see how ugly they are as I go.
I welded the piece on the top gap after making the bend.
53 Welded in the top bridge.jpg

Had some scrap angles left over that I cut in half to weld up the sides.
54 Use scrap  wedge from front angle cut.jpg

I'm going to have to do some grinding to make this fit in the cut out.
54.2.jpg

I cut the wedge in half, after grinding to fit, and used one half for each side.
Ugly welds. I don't know if they even qualify as welds.
55 Cut wedge in half and welded in place.jpg
Gonna have a lot of grindage to do.
55.1 Need to do a lot of grindage.jpg
 

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Discussion Starter #3
This is the paint I am going to use. It's as close to the finish on the ROPS as I could find. Should look good enough when passing by on a galloping horse.
56.0.jpg
 

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Shock - your pics aren't showing up (at least for me). Could I get you to try something? Edit your last post and instead of using the picture loader in the quick reply section, click on the "Go Advanced" box on the bottom and use the picture loader there. Let's see what happens... Thanks!
 

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Just a little advice on your welding. Turn your amps up and wire feed down. Also for “grinding”, you can knock all the heavy metal down with a hard disc(black) then buy a tiger paw(sand paper disc) and smooth it all out. Use the tiger paw on it like you use a polished on a car. Let the machine’s weight work on it. Don’t give to much pressure or you’ll put craters in it. Good idea though
 

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Discussion Starter #10
Just a little advice on your welding. Turn your amps up and wire feed down. Also for “grinding”, you can knock all the heavy metal down with a hard disc(black) then buy a tiger paw(sand paper disc) and smooth it all out. Use the tiger paw on it like you use a polished on a car. Let the machine’s weight work on it. Don’t give to much pressure or you’ll put craters in it. Good idea though
Naylor, thank you for the advice. I'm going to try this on my next project that involves welding.
 

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Discussion Starter #11
Ok. Now I can begin posting part two.

Again, I started with 1x1 square tubing.
2 Front. Started with 1x1 inch stock.jpg

Cut to length, angle cut, rounded and capped to match roof contours (as best I could).
3.1.jpg
3 Cut to length and angle cut to match roof contour.jpg
 

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Discussion Starter #13
If I didn't mention, I am using the mounting points for the roof to also mount the brackets for the lights.

The angle on this part of the bracket just doesn't work.
5 Need to level out one end..jpg

Back to the saw to make a cut.
6 Make a cut to allow leveling..jpg

After the cut, I did a little bending by hand to achieve the desired angle.
7 Bent to level.jpg
7.1 Will need to weld up the groove.jpg

I'll spare you to torture of looking at my "welds", and go right to the test fit after grinding.
8 Welding and grinding done.jpg
8.1 Will use body filler for gaps.jpg
8.2.jpg

They are pretty strong. I couldn't bend the competed parts by hand.
 

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Discussion Starter #14
The light bar is wider than the two short pieces mounted above. Therefore, I will need to extend mountings towards the outside of the machine on both driver and passenger sides.

After doing some measuring, I was able to determine they need to extend out about 7 inches each way. That will give me room to mount the light bar and the other two cube lights.
9 Cut two 7 inch pieces.jpg

This is how they will attach to the set of bars seen in the last post.
10 Ready to weld.jpg
10.1.jpg

Don't look at the next three pics if you are afraid of ugly welds.
11 Welded up.jpg
11.1.jpg
11.2.jpg
 

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Discussion Starter #15
I cut some 1x1 inch pieces to enclose the open ends of the mounts.

12 Cut 1x1 inch pieces for end caps.jpg

Then welded them in place.

13 End caps welded in place.jpg
13.1.jpg

After doing some more grinding, did another test fit.

14 Ground down and test fit.jpg
14.1.jpg

Then placed the light bar on the mounts to determine where to drill the mounting holes.

14.2.jpg
 

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Discussion Starter #16
After marking for the mounting holes, I began to drill the tubes.

15 Drilling holes.jpg

With one side drilled, I thought another test fit was in order.

16 One side done, test fit.jpg
16.1.jpg
16.2.jpg
16.3.jpg

Being satisfied with one side, I went ahead and drilled out the other, and test fit again.

17 Both side drilled and test fit.jpg
 

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Discussion Starter #17
The next step is to make a "hoop" or crossbar in an attempt to keep branches, etc. from hitting the front lights.

I cut pieces to form the upright for the crossbar/hoop.

18 Cut the pieces for the upright.jpg

Used these handy little magnets to hold in place as I welded.

18.1.jpg

Welded them up....

19 Welded uprights.jpg
19.1.jpg

...and ground them down.

20 Welds ground down.jpg
 

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Discussion Starter #18
I forgot to mention that the tubing used for the "hoop" is 3/4".

Using my magnets to hold things in place...

21 Getting ready to weld uprights in place.jpg

...I welded the uprights in place and did another test fit.

22 Welded in place and test fit.jpg
22.1.jpg
 

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Discussion Starter #19
LOL. I was waiting for someone to say that. Hopefully it will look a little less bovine like when I am finished. If not, we will have to come up with a new name for it.:bull_head:
 

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Discussion Starter #20
I cut the crossbar to length and made sort of a jig to hold it steady while I welded it in place.

23 Made jig and welded cross bar.jpg

23.1.jpg

Did a test fit after welding.

24 Test fit cross bar.jpg

After grinding down the welds, I put the mount back in place to make sure nothing moved.

24.1 After grinding down welds..jpg

Some more grinding and welding to fill in the gaps, and used this paint again.

27.0.jpg

Finished product.

27.1 Painted and mounted.jpg
27.2.jpg
27.3.jpg

Next I will start on making a switch panel and begin the wiring.
 
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