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Discussion Starter · #1 ·
Hello all. With winter in full swing no better time for some custom work.
I am currently doing some light bars. I've installed 2 9" LED lights for back lighting. Next is the 42" bar for the front. Thinking of welding tabs to roll cage. I will be installing a roof and a windshield. Not sure if I am going to mount up high or above the hood. If I am going up high in front of windshield what is the best way to run wiring to the light bar? Thank you all for your input.
Jamie
 

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The best/cleanest way is to drill a hole at the bottom of the roll cage, and at the point closest to the light bar, and fish a string through the cage and pull the wires thru. It's kinda a pain, but the reward of a good clean install is worth it. You didn't mention what vehicle you are installing on, but I know that the new "non round" roll cage on the 900's and 570's are a pain for running wiring inside, but I managed to do it for my 6" reverse light that I mounted on the back of the roll bar. The traditional ROUND tubing roll bars are a lot easier to fish the string and wires through.
 

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wire wrap and wire ties are the easy and simple and quick
 

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Discussion Starter · #4 ·
The best/cleanest way is to drill a hole at the bottom of the roll cage, and at the point closest to the light bar, and fish a string through the cage and pull the wires thru. It's kinda a pain, but the reward of a good clean install is worth it. You didn't mention what vehicle you are installing on, but I know that the new "non round" roll cage on the 900's and 570's are a pain for running wiring inside, but I managed to do it for my 6" reverse light that I mounted on the back of the roll bar. The traditional ROUND tubing roll bars are a lot easier to fish the string and wires through.
Thank you pondskum. I have a 2015 900XP. Wasn't sure about the whole cage thing. Like you said old round style cage would be easier. My father in law is a excellent fabricator. So we are gonna weld some tabs to the cage and make mounts so lightbar is out away from windshield. I will post some pics after the install is done
 

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I'll try to remember to snap a pic of where I drilled my cage later on. I'm at work right now, so don't have access to take pics.
 

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Full draw, EMP sells a clip-on (bolt-on) side mirror specifically designed for the non-round 900 ranger roll cage which, because of the rubber gasketing on windshields, and I presume, on doors; does not interfere with the use of either. I have approached them, unsuccessfully so far, about fabricating light brackets using their mirror attachment design, to provide more flexibility in placement and removal, and less effect on finish than welding would cause. Having thick trees and brush in my riding area, I'm not sure if I would want my lights mounted just above the hood, or just below the roof. Just throwing this out for an option to welding.
 

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Discussion Starter · #7 ·
TG. Thank you for the input. It seems like mirror mounts would make it wider?? I'm doing a 42" bar. I definitely don't want to go above roof. And just above the hood would be wasting good light. I dont bushwack so to say. But get into a low limb once in a while. Was thinking about fabricating a brush guard for the light. Guess I will have to get it on first
 

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I did a 50" curved light and mounted the brackets in the top corners of the trough where the lock n ride windshield sets and fit pretty good. Trimmed the windshield about 1/2" in those corners and it still goes right in place. Mounts up right below the roof and the roof will even still come off if I need it too. As far as the wiring, I ran it on the outside this time around, zip ties with the little hole to screw it to the side of the roll bar. I did put the wiring in heat shrink so it doesn't look like total crap, though. Land vehicle Vehicle Tire Automotive tire Motor vehicle
 

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Here's how I ran my wiring through the cage up to my rear light bar.

Windshield Glass Automotive exterior Auto part Automotive window part

Automotive exterior Ceiling
 
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