DIY lightbar

[Sinkoumn]

This is my DIY lightbar, took 2 days to make and cost just under $160 (including lights). I am not done with the wiring, that is going to have to wait until early March (boat's up north for the winter).

I still need to cut off the bolts at the nut and finish with a cap, but you get the idea as to how it will look.

All of my parts were bought at either Home Depot or the internet.

Basically, I bought an L shaped piece of 1/8" thick aluminum from HD. Marked out all drilling holes for mounting the lights to be a symmetrical staggard formation (3 front and 3 back). Drilled holes and rounded the edges.

For painting, all I did was rough sand the aluminum and then washed the entire bar with detergent in the bathtub (I made sure I didn't touch the bar with my skin after it was clean and dry - oil = bad paint). I applied one spray, followed by a wet coat of automotive primer from a spray can. Let that dry for about 30 minutes, then took a hairdryer and basically cooked the primer on the entire bar. Once done, I sprayed with Rustoleum Metallic flake paint - two coats, wainting an hour and a half in between coats. The bar came out exceptionally well, sparkly .

After that, pretty straight forward - mounted everything up. Two days and out.

Just wanted to share, very easy project and an easy way to save some coin on a lightbar if you are looking to get one for docking and extra light at night.

[Sinkoumn]

Mas

[Sinkoumn]

Mas MAS

[HHI Dave]

Man, fine job! Looks just like a big $$$ lightbar to me.

I'm guessing you got the lights on Ebay. Are they automotive driving lights?

Great DIY.

Thanks for posting the pics. If I hadn't just snagged a Mako 3-light bar on Ebay myself (for under $100.00 by the way) I would definitely be following your lead.

Make sure you post pics once you finish doing the install on your boat.
(But please don't change your profile pic because it brings me joy every time I see it. )

[Sinkoumn]

Here's the shopping list:

Item..........................QTY.....COST...........LOCATION
-------------------------------------------------------------------
L shaped Alum. Bar.......1......$15.00..........Home Depot
Pilot PL-704B................6......$95Shipped...eBay.com
Rustoleum Primer.........1......$3.00.............Home Depot
Rustoleum Spray Paint..1......$5.00.............Home Depot
1 7/8" Bar clamp...........2.....$38Shipped.....DIYwake.com
Various Washer/bolts....--...~$10.................Home Depot
30amp Relay.................3.....Free(included with Lights)

[jjaszkow]

Nice job. That's going to be a sick addition to your boat.

Are you going to put the wires in flex loom to hid them when you mount this on the tower?

[Sinkoumn]

I am planning on running each set of wires (hot and ground) to the sides and middle, putting heat shrink tubing around each and will then be left with essentially three lines (Left, Middle, Right).

Since the hot and ground will be joined into one line, I will just use the flex loom to cover all the wire clusters and to make it look better. I'm still trying to decided where I want the hole in the tower to be - I'm leaning toward putting it right in the middle to keep all of the lines of the lightbar symmetrical.

I might also be adding a quick connect/disconnect where the three lines coverge into on line.

I'll be sure to post up more pics when I get running on the wiring later next month.

[jjaszkow]

I like both those ideas. I am a big fan of clean, symmetrical wiring, and that sounds like you are on the right path. Great idea on the quick disconnect, you will thank yourself the first time you have to remove the lightbar.

[Styk33]

I like the poster in the clamp reflection in your second pic in your second post