Fabricator to make third brake light bars - Defender Source
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  #1  
Old February 12th, 2009, 10:02 PM
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Fabricator to make third brake light bars

I am looking for someone with a tube bender to make the pipe part of the third brake light bar. I will front the money for a bunch of them. If you can weld the plate parts on, all the better. If you can get them galvanized, all the better.

PM me.
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  #2  
Old February 12th, 2009, 10:06 PM
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I will check with the metal Shop at school I have mine off the truck so it will be easy to take to them
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  #3  
Old February 12th, 2009, 10:07 PM
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Doesn't Crazy George have a few? Not free, but cheaper than making a bunch.
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  #4  
Old February 12th, 2009, 10:51 PM
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Yes, but the stock ones are powered coated which is their downfall. Painted or galvanized would last forever. I could sell off the spares to those who need them (which seem like pretty much everyone at this point).

Ron
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Old February 13th, 2009, 10:10 AM
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Quote:
Originally Posted by evilfij
Yes, but the stock ones are powered coated which is their downfall. Painted or galvanized would last forever. I could sell off the spares to those who need them (which seem like pretty much everyone at this point).

Ron

The factory ones are not powder coated. They are plastic coated, and that causes their demise. We strip them and then properly powder coat them and they last for years (haven't had one come back rusted yet).

You are right the plastic coating on them causes rust quickly.
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  #6  
Old February 13th, 2009, 10:27 AM
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Whatever coated they are crap, mainly because the screws for the brake light puncture that coating.

How do you strip them? Heat?
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Old February 13th, 2009, 01:11 PM
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BTW George get $385 for these things (with the light though). We put a cage in the lemons car for that.
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  #8  
Old February 13th, 2009, 01:41 PM
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Originally Posted by evilfij
BTW George get $385 for these things (with the light though). We put a cage in the lemons car for that.
Wow... I'm glad I don't trust my life to anything you make. The DOM tubing for a proper cage would cost more than that. What did you use black pipe from Home Depot!
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  #9  
Old February 13th, 2009, 02:01 PM
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I did not make it. Maybe $385 was an understatement by a little bit.

It is not bad. It is DOM, one of the guys got a great deal on it IIRC it was $350 for all of it, plus the extra for the high denisty foam padding. It meets spec. Welds are not stacked dimes (no, I did not do them), but there is good penetration and the design is sound.

http://www.lotustalk.com/forums/f223...ml#post1210672

What do you think? I bet it is stronger than the stock NAS cage.

Ron

PS how do you get the plastic coat off the light bar.
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  #10  
Old February 13th, 2009, 02:13 PM
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How many are we talking? I can do them up on my bender, but would need to pick up a 1 1/4" die. I can do the plate as well.

PM or email me and we can chat.
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  #11  
Old February 13th, 2009, 02:38 PM
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PM sent.
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  #12  
Old February 13th, 2009, 02:40 PM
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PM replied to!
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  #13  
Old February 13th, 2009, 08:53 PM
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would anyone entertain fabricating this out of anodized aluminum, we can do that or steel?
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  #14  
Old February 14th, 2009, 06:43 AM
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We have done a ton of powdercoating the third light bars, brush bars, 110 cages, etc, and Mike is dead right- it is all plastic. Our powdercoater is totally convinced they are all dipped, and the plastic forms a shell so to speak, but isn't actually bonded to the tube. Consequently, the rust runs under the coating once it starts, and then big pieces flake off. I have to burn it all off before he can powdercoat, as sand blasting- with different mediums- is a very slow tedious and expensive process. And I mean burn, like in a big bonfire- flashing it w/ gasoline or other accelerant ( oil on manifold)doesn't touch it. I have a couple light bars going to the PC next week, and have one light I think. Oh, and one more thing- you can powdercoat over it, but the pc isn't bonded to the metal. We found by preheating the plastic coated parts, the charge and tackiness allowed the pc to adhere, but for how long, no one knows. So, we always burn the plastic. I would be interested, if anyone has done the pc over the plastic, to know how it holds up.
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  #15  
Old February 14th, 2009, 11:24 AM
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That bar is a crappy design anyway! If someone is going to fabricate a few there are many ways to improve on the original design!
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  #16  
Old February 14th, 2009, 12:02 PM
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Quote:
Originally Posted by Departing90
That bar is a crappy design anyway! If someone is going to fabricate a few there are many ways to improve on the original design!
The bar isn't a crappy design, just a bad plastic coating. I'm not sure how you could improve the design other than materials.
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  #17  
Old February 14th, 2009, 01:00 PM
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Quote:
Originally Posted by Jeep Rescue
The bar isn't a crappy design, just a bad plastic coating. I'm not sure how you could improve the design other than materials.
I am not a fabricator so wouldn't know how to go about it but the light housing is flimsy at best and the plastic cover does not even sit flush on a brand new unit. An across LED type of light would also be considerabley brighter & more durable! seems overkill for a light bar and no where near sturdy enough as a crash or roll bar!

It looks the part though on a D-90.
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  #18  
Old February 14th, 2009, 01:41 PM
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Who else would be interested in a new light bar (no light, just the bar)?

Jeep rescue. Your revised pricing seems good. PM me a price for a complete prototype.

Mike at ECR, what do you think of the cage? I respect your opinion on such things.

Best,

Ron
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  #19  
Old February 14th, 2009, 01:50 PM
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Quote:
Originally Posted by evilfij
Who else would be interested in a new light bar (no light, just the bar)?

Jeep rescue. Your revised pricing seems good. PM me a price for a complete prototype.

Mike at ECR, what do you think of the cage? I respect your opinion on such things.

Best,

Ron
Dibs pending picture & price.
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  #20  
Old February 18th, 2009, 09:37 PM
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I bought a used 3rd light bar from someone on the forum. The price was great but proved to match the condition. At first I was bummed and figured I should have just bought the NOS one from RDS. But after reading this thread I am kinda happy I have to get the bar refinished.

FWIW, I used a heat gun and a scraper that has a razor blade and the plastic came off pretty easily.

There was a fair bit of rust and some of the metal is pitted pretty good. I gave the rusted parts a hit with the hammer and chisel and they seem to still have enough material left.

At this point I cannot decide if I should wire brush, prep and cover with POR-15. Seems I would then have to primer and then paint for UV protection.

OR... get the bar sandblasted and bring it to the Powdercoaters.

Price/Time seem about the same but what would last and look the best?
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