I replied to a thread that was asking about a DIY light bar, but the post does not show up. This forum is great for brainstorming, documenting and sharing, so here it is, hope this thread shows up.

I plan on getting few things done on the car next two weeks, tie rods, ebrake, fog light, thermostat, ..., thinking while I am at it, it wouldn't hurt to add one more thing on the weekend list. The truth is, I really got fed up about the weak head lights from factory and everyone around here drives trucks with their lights turned up a notch or two... so here is the DIY plan on installing a quad lower grill rally light bar, similar to the Palo Uber.

So far in the garage, I got 1/8 thick, 1-1/2" and 2" sides and 36" long aluminum angle beams ($13, $15). Left over IKEA Grandtal double bar towel racks (2x $6.99). 8mm x 50 and 60mm bolts. The beams and rack mounts are pretty sturdy. I am banking on the beams are long enough for the lower bolts on the bumper back plate - appears to be just about right, so I don't have to get longer ones and cut. Also banking on the perpendicular "lips" on both side of the bumper back plate to be even for the angle beam to rest on, so I don't have to pad with square tube spacers. Other than that, get 4 x 500FF ordered, wait until the weekend and measure and drill. The IKEA rack mounts will have one extra hole drilled on the bottom to have an additional secure point to the angle beam.

This plan is captured in the attached photo, hope all goes smooth, may not have the lights by this weekend, will come back and share results when it is complete. In the mean time feel free to chime in and share your thoughts.

Cheers.

-X

 

The lights are in. Basically followed the plan like a Uber install with Altar arrangement, I drilled holes also for the Uber setup, but decide not to have the gap in the center.

It was somewhat more customization than I anticipated - on top of drilling, it needs cutting too. For those who got an Alta bar before they are out of stock at a discount price - you got a good deal! If I was not lined up with a weekend of car wrenching and only want the lights, I probably would have ordered a kit from VIP or outmotoring.

The bar is working as expected, though shakers a little when going through bumps, but definitely not bad, I will add some dampings when more observations are available. For people want to DIY the bar, choose materials and building blocks with even more rigidity! - what was solid in my hand turned out not solid enough for cars. sub-millimeter movement will be observable when lights are projected. Don't know how the Alta and Uber compare.

I did also get tie rods, thermostat done. so after all, it was alot of fun and the weather was nice. I did not appreciate the complexity for getting the thermostat in, and for both tierod assemblies, I had to cut them off before the jam nut as they were rusted - using a hack saw!

For the lights, picture worth a thousand words. I was working by myself, and was pretty dirty and occupied the whole time, shots are limited but should deliver the concept. Attached are three photos. 1) light bar construction and mounting on the bumper plate. 2) and 3) are photos of the car with and without the lights on. Night visibility is greatly improved.

Cheers.

 

Very nice!

 

Any problems with overheating yet?

 

That looks stellar. Nice DIY.

 

I'd love to hear about any sort of overheating problems. If they're working like a charm and there's no temperature difference, I'm definitely going to try this out!

 

Dan, there have not been any overheating issues. I do not expect the light as a cause either. Feel free to share your thoughts and rationales, and perhaps I can examine better. Two dilemmas though: I am in MN, ambient is cold now, this may hinder any cooling issues to show up. I am fighting with a break problem right now, test may not happen right away, but I will update when new information is available.

Before we have facts and further observations, this light setup is no different than the Alta and Uber products, many members here got them, I am not aware of any overheating issues reported, so using those commercial products as a reference, we should not expect overheating. Left me know if there are particular concerns. Best!

 

I took the car out after the brakes were done today. Stretch it abit while I was bedding in the new rotors, cooled down abit, and went through a car wash after a long wait. The engine was running the entire time and did not see any issue with over heating, it was in the 30's today in MN, and probably the best I can test on overheating before next spring - I personally would not anticipate any issues, and the Mini temp gauge really does not tell a whole lot either. Anyways, for now "working like a charm" is the conclusion. Cheers.