I started with a 2"x2"x1/8" angle steel 48" long, and ended up with a sweet, custom light bar for my 94 GMC Jimmy. I had the 3 lights already, so the total cost of the angle steel, screws, wire, switch, etc... $36.72!

 

thats an awesome light bar. i would love to make something like that for mine. what would it cost me to have you fab one up for me? again awesome work.

 

nice work! came out all pretty too! How did you run the wires by the way?
EDIT: How about some dimensions? I'd love to be able to build something like that myself!

 

awesome light bar...makes me rethink the use of the stock rack cross member.
simple, looks good and functional...what more could you ask for.

 

The wires are ran behind the angle steel and through a hole I drilled in the roof on drivers side (also behind angle steel). The dimensions are 35" between the factory roof rack. I added 1/8" so it fit snug. I cut the angle steel 2" longer on each side so the overall length is 39-1/8". The front of the angle steel was cut and bent to fit between the roof racks and the top of the angle steel was bent to hang over the top of the roof rack. The screws are deck screws bought at Lowes, pre-drilled and screwed right into the ends of the roof rack. I used a Sawzall with a metal blade, a 4" angle grinder, a drill, and a plumbing torch to make the bends easier. Slap on a few coats of paint and it's good to go. I'll post pics of the back of it tomorrow, hope this helps all you DIY'ers.

 

Wow...very nicely done. I love how clean it looks. I'm with warthog...seeing all the custom light bars I kind of wish I did that instead of using my roof rack lol.

 

Once again nice job Rob.You should take some orders and make some $$ off your skills.

 

That's funny. My roof rack is wider than yours, by about 2.5 inches. I would think all the first gens would be same, but I guess yours is the newer version. My actual rack is also different. I'm not sure I could just bolt one on like you did. How much does your light bar move? As in, if you push on a light does the bar twist with it? I guess what I'm asking is is there anything you would have done differently if you did it again?

 

Good work! No welding required either.

 

That light bar is awesome! I think it looks professional.