Thanks... I won't lie to you...I am (and will be for some time!) shop-vac'ing the heck out of my basement after the carnage!Originally Posted by JHarris1385
Lots 'o' debris & dust from cutting (carbide cutter), grinding (dremel, bench wheel grinder), drilling (hand drill), filing (hand file). I've had this thing sitting in its original box since February and finally got the time & inclination to work on it now!
**I was concerned before I bought it that the light bar had a non-adjustable angle strictly for placement atop the forward roof directly above windshield as on Liberty Renegade. After stalking some Jeep Liberty's...lol...each light (Hella) does have an up/down angle adjustment which I have not played with yet and am assuming will be sufficient.
Alot of the work involved a simple mock-up & measurements on my VX. Sitting back and deciding what I didn't like (the overhang, height from roof). Spending like 4 hrs. after work in the evening contemplating & actually working to shorten the overhang without getting too excessive and ruining the light bar. Than thinking @ work what I needed to do to add additional support so it could be a "stand-alone assembly" rather than a "bolt directly to your roof assembly" as it was intended. Than spending more time after work laying-out what I decided to use for support (Ldubs favorite material..lol.) & cutting it out to match shape of bottom of light bar & marking, drilling the mounting holes & hole for wiring harness w/rubber grommet. Than spent another evening robbing one of my original roof racks of its support brackets and modifing them (more measuring, cutting, grinding & filing, plus mock-up) to get the height & level mounting face right. Then buying some slightly stronger bolts (allan bolts..one per side) to fasten the support brackets to the new light bar bottom... which had one issue that I had to remove each outboard light (left + right) to drill & fasten the support brackets and than re-install outboard lights. Finally, tearing it all down to clean dust, primer & paint flat black the support piece (you know, the one made from Ldubs favorite material) and after drying..re-assembling the whole unit. For now, I capped-off the left & right side ends of the light-bar (after I cut off to remove the over-hang) with that screen you buy for auto-body work (to spread bondo over) which I cut to shape using a template & painted flat black & attached with black RTV. I may make actual plastic pieces instead later...but, for now It seems to work & look okay. I don't see much moisture ever getting inside as there is more plastic "baffles" if you will inside and the wiring is all done with plug-in connectors so there really is no bare wiring inside.
The finished light bar will have a plug-in wiring harness (not currently wired up...harness is coiled-up & tie wrapped presently) so that all you have to do to remove it is disconnect plug, remove the same single allan-screw you have on a stock VX roof rack support for each side, pick-up and swing off roof!
Total cost of project:
Jeep Liberty Renegade light bar on ebay $185 plus $20 shipping = $205
Support piece (Ldub's favorite stuff) 44"L X 8"W X .25"thick= $20
Rustoleum Primer from Lowe's (had on hand for repainting wiper arms)=$4
Rustoleum flat black paint from Lowe's (also from wiper arms)=$4
Body supply screen from Advance Auto (2 sheets in pack) = $4.50
Tube of black RTV = $3-$4
hardware...7 bolts scavenged from light bar kit, bought 7 nuts, washers, lock washers, 2 metric allan bolts w/nuts + lock washers for support bracket mounting, re-used the 2 VX allan bolts used as fasteners for roof mounting. = maybe $4 total from True Value Hardware.
already had all power tools & bits & accessories on hand.