started with a 5' length of rectangular steel tube that provided the
'beef'. Although the holes for the lights could be cut using a large hole saw or a
handheld jigsaw, I chose
to throw the bumper onto the C&C machine. This allowed me to
trim the ends at the same time the holes were cut.
I know this isn't
something that everyone has in their garage... but it sure made it
easier to cut though the 3/16 steel!
*note* If you want to do something similar, but lack the access to
drilling or cutting tools necessary to cut these holes, you can pick
up a 'Bumper Blank' from Glenn at Rocky
Road Outfitters at a surprisingly low cost.
I chose to use three lights on each side to make it easier to wire
with the stock harness. I also cut out the center hole for a 2"
receiver that I planned to flush mount for a clean look.
The steel was
going to be beefy enough to take the abuse, but I was worried about
the small area between each light. If a rock were to hit the light I
could replace it on the trail if I needed to, but if that small
section of metal in between got hit there would not be be much support
behind it. The answer to this problem was welding in a 3/8"
support rod in between each light. Click on the four frame picture to
the right to see how that problem was solved.