Roll Cage Mounted Lights - Defender Source
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  #1  
Old December 25th, 2006, 08:20 PM
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Will Peters
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Roll Cage Mounted Lights

To mount lights to the top of the cage do I just drill out the mounts? Do I need to remove the threaded part or just drill it all out?
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  #2  
Old December 25th, 2006, 08:24 PM
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lights should just bolt in the threaded mounts of the roll cage..
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  #3  
Old December 25th, 2006, 08:27 PM
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Will Peters
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My hella's (FF 1000's) bolts are quite a bit bigger then whats up there.
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  #4  
Old December 25th, 2006, 09:46 PM
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I wanted my lights in a different position. So I got a flat stainless bar and drilled holes to attach it to the roll bar. Then I could drill the mounting holes in the bar at the desired position for my lights. That way you don't have to mess with
your original mounts.

You could also source individual light mounting brackets to attch to the roll bar attchment points, and just attach the lights to those. Such light brackets usually have holes big enough for any size lamps.
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  #5  
Old December 25th, 2006, 11:58 PM
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Quote:
Originally Posted by NashvilleRedD90
My hella's (FF 1000's) bolts are quite a bit bigger then whats up there.
I believe the roll cage mounting holes for aux. lights are M8 threads.
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  #6  
Old December 26th, 2006, 01:07 AM
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Will Peters
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Yeah, I think they are. But my hella's use 11.

I'll figure something out later... I'll probably just drill a bigger hole in the mounts. No big deal I guess.
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  #7  
Old December 26th, 2006, 01:15 AM
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Just my 2 cents...if you drill them out, you can't go back. If you use M8 bolts, you don't have to modify anything...


Cheers...
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  #8  
Old February 5th, 2010, 06:47 PM
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Carl Jonsson
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I jumped the gun and drilled out the mounts on my roll cage to fit some new Hellas. I didn't know they were threaded, had I know I probably would have kept it as is. Right now the Hella hardware sits way to close to the cage bar. The nuts can't spin because they hit the bar. I need to get them out and away from the bar. I probably should get some brackets to move them out and away from the bar. Any suggestions on what to do here? I thought of getting longer bolts but these flat and square T-bolts can't be found anywhere. Has anyone found any good individual mounting brackets? Any other suggestions?
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  #9  
Old February 5th, 2010, 07:29 PM
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Quote:
Originally Posted by Grover View Post
Just my 2 cents...if you drill them out, you can't go back. If you use M8 bolts, you don't have to modify anything...


Cheers...
X2...don't drill. Figure out a better way or just buy new lights. not worth it.
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  #10  
Old February 5th, 2010, 10:28 PM
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I appreciate the advice. I wish I had read it before I drilled them out. I didn't realize they were threaded. Now that I already screwed up, what's the best way to proceed?

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Originally Posted by specops1526 View Post
X2...don't drill. Figure out a better way or just buy new lights. not worth it.
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  #11  
Old February 6th, 2010, 01:27 AM
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The problem with the roll cage mounts is that they only work with lights where the mounting bolt can rotate freely. On lights like Hella, the mounting bolt does not rotate because it has a square flat head. That is, if you have Hella lights, these mounts are useless because if you attach them they'll end up pointing in whatever arbitrary direction it happens to be in when the bolt tightens. I looked for replacements for the Hella bolts but they don't seem to exist. I want to stick with the Hella's I picked out so I'll probably have to fab a flat bar like Marc did or individual mounts.
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  #12  
Old February 6th, 2010, 08:46 AM
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not sure if I understand, but here goes...
if the nut will not fit just shave off two sides with a grinder so it will fit up in there, then spin the light around to tighten
if the bottom of the bolt is hitting your roof, then shim it up with some washers
kind of hard to diagnose/rig when not there
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  #13  
Old February 7th, 2010, 01:31 AM
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Thanks Jon.

The first problem was that I drilled out the mounts before finding this thread. The 2nd problem is that the Hellas have very special bolts that can't be replaced. They have very thin, very wide and very flat, square heads that just about fits into the Hella light mounting bracket (that holds the light). When the bolt is in position on the light it cannot be rotated which means if I spin the light around to tighten it, it might end up facing backwards or sideways when it has been tightened (that is, if I had a threaded mount). The third problem was that the nut that is supposed to fasten the special Hella bolt is touching the roll bar so there's no way to spin it or even get a wrench in there. See picture attached above.

Long story short: don't drill out the roll cage brackets and if you have Hellas you'll probably have to get a bar to mount to the brackets to so that you can mount the lights to the bar.

Thanks.

Quote:
Originally Posted by Jon_Winningham View Post
not sure if I understand, but here goes...
if the nut will not fit just shave off two sides with a grinder so it will fit up in there, then spin the light around to tighten
if the bottom of the bolt is hitting your roof, then shim it up with some washers
kind of hard to diagnose/rig when not there
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  #14  
Old February 7th, 2010, 02:47 AM
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Pull out the hella bolt and put a new one in. It's not that hard. Doesn't fit? Grind the top down. Magic.
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  #15  
Old February 7th, 2010, 01:39 PM
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Originally Posted by Buckon37s View Post
Pull out the hella bolt and put a new one in. It's not that hard. Doesn't fit? Grind the top down. Magic.
Couldn't have said it better myself. A bench grinder can be an invaluable tool!
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  #16  
Old February 7th, 2010, 09:11 PM
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You're a genius, Buckon 37s. I've looked at Mcmaster, etc for a replacement but nothing comes close. Besides, it doesn't solve the problem because I still have to move it over to get clearance from the bar. I'm going to fab a stainless bar to attach them to. I can then also run the wiring underneath of this bar.

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Pull out the hella bolt and put a new one in. It's not that hard. Doesn't fit? Grind the top down. Magic.
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  #17  
Old February 7th, 2010, 11:02 PM
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Quote:
Originally Posted by Manimal View Post
You're a genius, Buckon 37s. I've looked at Mcmaster, etc for a replacement but nothing comes close. Besides, it doesn't solve the problem because I still have to move it over to get clearance from the bar. I'm going to fab a stainless bar to attach them to. I can then also run the wiring underneath of this bar.
Grind down one side of the nut. Or re-tap the hole to a new bolt size and replace with that. Or drill a new hole and weld on a washer. Or cut off the tabs and weld on new ones.

Or don't run the lights because all they are actually good for is keeping you out of most parking garages. Unless you're a desert racer.
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  #18  
Old February 8th, 2010, 12:15 AM
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Thanks MacGruber. I hope to be as handy as you one day. Haven't graduated to welding yet. Bracket is the best option for now. The Hella 550's don't make much of a difference in height. I am already kept out of most parking garages.

Quote:
Originally Posted by Buckon37s View Post
Grind down one side of the nut. Or re-tap the hole to a new bolt size and replace with that. Or drill a new hole and weld on a washer. Or cut off the tabs and weld on new ones.

Or don't run the lights because all they are actually good for is keeping you out of most parking garages. Unless you're a desert racer.
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  #19  
Old February 8th, 2010, 12:22 AM
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Thanks MacGruber. I hope to be as handy as you one day. Haven't graduated to welding yet. Bracket is the best option for now. The Hella 550's don't make much of a difference in height. I am already kept out of most parking garages.
I was thinking if you wanted to be superblingy, you could bolt on one of the desert light surrounds with the AL tube clamps. That would fix your issue and make it all purdy. More cash though.
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