Metal Working. Again. Well, trying to. How do I do this?

[WhatExit?]

I have a LED Light Bar that I need a bracket for.

This bracket needs to be similar to this design but the dimensions are, of course, different.

I figured I could bend a flat bar stock purchased at Home Depot, drill the holes in the sides and along the length for mounting it to my truck (after painting it).

Flat bar from HD...

Of course my thinking was based on bending it nicely, square and with fairly sharp bends.

How the hell am I going to do this? I have no vice, no metal working tools. Not even a drill press so I drill everything by hand.

Any suggestions?

More info: The bracket needs to go over the top of the light (not much different than underneath but the mounting holes are not in the center of the sides so it matters only when drilling the 2 holes on each side. The LED light is below (pics) and it's about 13 ¼" long approx.

Thanks in advance

 

[RiverDave]

Somebody has to make a bracket for that light Dan.. you are gonna he miles ahead buying the factory one. Just google the part number.

If you had a vice into at least make the bends I would say give it a go.. but no vice and it’s gonna be pretty out of the box on how you are gonna do this..

 

[hallett21]

Would having an “L” help at all? Home Depot sells that.

Not sure if you have an equivalent but Industrial Metal supply here in CA has all kinds of different pre bent steel and aluminum.


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[RiverDave]

I believe this uses the same mounting hardware judging by the two holes in the side. They have two brackets you can pick from.

NITRO Maxx 105W 13" LED Light bar

NEW Performance you won't believe - unrivalled distance and width outputs NEW Widr® Optic - This unique reflector delivers market leading output, achieving huge distance with excellent spread NEW Usable light - now 900M Designed and Made in Australia for the toughest environments on earth...

ultra-vision.com.au

 

[Flying_Lavey]

Larger C clamp and the edge if a strong bench could work.

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[WhatExit?]

I believe this uses the same mounting hardware judging by the two holes in the side. They have two brackets you can pick from.

NITRO Maxx 105W 13" LED Light bar

NEW Performance you won't believe - unrivalled distance and width outputs NEW Widr® Optic - This unique reflector delivers market leading output, achieving huge distance with excellent spread NEW Usable light - now 900M Designed and Made in Australia for the toughest environments on earth...

ultra-vision.com.au

You're good Dave. That's where these high performance lights came from...Australia. I didn't get that particular bracket but it won't fit in the space I have in the front opening of the truck.

And from what I've seen LED lights are all pretty different in size and I need a bracket for this light

Would having an “L” help at all? Home Depot sells that.

Not sure if you have an equivalent but Industrial Metal supply here in CA has all kinds of different pre bent steel and aluminum.

I've already used 2 - 4" angle brackets and they almost worked but I really need a 1-piece bracket.

Larger C clamp and the edge if a strong bench could work.

Yup, I've got clamps. And a wood bench made of 2x6's so it's not ideal.

So I've been thinking about clamping a thicker, larger piece of flat steel bar to this ⅛" thick bar and using it to bend it. But I'm also thinking, how do I hold the piece of bar I'm bending so I have a chance at bending it into a sharp corner?

 

[WhatExit?]

Lower opening in front of truck is where this LED light bar is going - dark rectangular area between tow hooks...

 

[Universal Elements]

Mine is an older model, looks like the same size opening. They do have those brackets made already. I’ll see if I can dig up where I bought them.

 

[monkeyswrench]

To make a sharp 90 you may relieve the back/inside of the angle with a cutoff wheel...score it basically. You can also heat with a small propane torch or mapp if you don't have a oxy/ac torch. Anything is better than cold...the outer will get small cracks. To clamp it, use a C-clamp and your tow hitch...sturdy for what you need, and sharper angle than a 2x4.

 

[HOOTER SLED-]

Heat that bitch up...throw it in a vise to hammer the 90. Come on maaaan....you're acting like one of those lil girl millenial liberals you're always talking shit about....

 

[jones performance]

id use thinner material, light dont look big or heavy enough to warrant 1/8 thick.

 

[RVR SWPR]

Good excuse buy a Vice you will use for years.

 

[coolchange]

Do you have any tools? Your not going to control that bend with out a press brake. Easiest would be cut then weld.
Do you have a bottle jack? How about 2 pieces of angle iron? How’s the hitch on that truck? Score the metal outside to start the bend. Then make a press brake. With heat.

 

[Ziggy]

id use thinner material, light dont look big or heavy enough to warrant 1/8 thick.

That's the first thing I thought too, even 1/16 would be plenty.

 

[WYRD]

No advice on bending without a vice but please for the love of God, don't be one of those dick's that thinks it's ok to drive around town with led bars on as normal driving lights

 

[WhatExit?]

To make a sharp 90 you may relieve the back/inside of the angle with a cutoff wheel...score it basically. You can also heat with a small propane torch or mapp if you don't have a oxy/ac torch. Anything is better than cold...the outer will get small cracks. To clamp it, use a C-clamp and your tow hitch...sturdy for what you need, and sharper angle than a 2x4.

I like this idea - didn't think about that. I could score a straight, square cut using a hacksaw - think that would work?

I'm a woodworking guy that never learned metal working, welding, etc. I know my way with tools but metalworking is not something I'm set up to do.

Do you have any tools? Your not going to control that bend with out a press brake. Easiest would be cut then weld.
Do you have a bottle jack? How about 2 pieces of angle iron? How’s the hitch on that truck? Score the metal outside to start the bend. Then make a press brake. With heat.

Lots of tools but not for metal and certainly no press brake I have a bottle jack (or 2) but no angle iron (I can buy it). Hitch is 3" with nothing in it yet (got a fifth wheel hitch in the bed though). I can't bend steel and you expect me to "make a press brake"

No advice on bending without a vice but please for the love of God, don't be one of those dick's that thinks it's ok to drive around town with led bars on as normal driving lights

Good advice...

My lights don't get used on the road (unless no one's around )

 

[hallett21]

Maybe this?

Eastwood 4 Inch Vise Mount Press Metal Brake

Make reinforcement channels, ribs and much more all with one convenient, easy to store tool.

www.eastwood.com

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[WYRD]

f250 lower valance light mounting brackets - Google Search

Seems like a ton of different options for cheap I'm sure you can find something that would work?

 

[cofooter]

You need a vice at least, and a bit of heavy persuasion, like a small sledgehammer, for a decent bend!!!

 

[WhatExit?]

Maybe this?

Eastwood 4 Inch Vise Mount Press Metal Brake

Make reinforcement channels, ribs and much more all with one convenient, easy to store tool.

www.eastwood.com

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I like that. Very cool.

Vice: nope
Eastwood 4 Inch Vise Press Metal Brake: nope
Heavy duty workbench: nope
Steel bar: $6.00
Cost of bending $6.00 bar: priceless

 

[WhatExit?]

f250 lower valance light mounting brackets - Google Search

Seems like a ton of different options for cheap I'm sure you can find something that would work?

Thanks! I need to install the light I have but there are some brackets that might work.

This is what I'm trying to do...

Lower Grille Mount 12" LED Light Bar Kit For 2017-2022 Ford F250 F350 F450, (1) High Power LED Lightbar, Bumper Mounting Brackets & Wiring Switch

iJDMTOY Lower Grille Mount 12" LED Light Bar Kit For 2017-2022 Ford F250 F350 F450, Includes (1) High Power LED Lightbar, Lower Bumper Opening Mounting Brackets & On/Off Switch Wiring Kit

store.ijdmtoy.com

 

[rivermobster]

Heat that bitch up...throw it in a vise to hammer the 90. Come on maaaan....you're acting like one of those lil girl millenial liberals you're always talking shit about....

The truth always comes out eventually don't it? Gotta give ok MMD credit though, seems he is Trying to (finally) change up his style.

 

[buck35]

Go visit @monkeyswrench

 

[JUSTWANNARACE]

Cut 2 pieces a few inches long off the end of that flat stock.

Score the inside of where you want bent.

Put one piece you cut off on your bench sticking out just a bit past the edge of the bench. Place flat stock on top then put the other cut piece on top of that

Use your c-clamp and clamp the flat stock to your bench(long side away from the bench). Basically sandwiched in between the 2 small pieces you cut.

Push down on the long side while using a hammer to hit the stock closest to the bend as possible.

Continue till you get to 90⁰

 

[Icky]

Go to a damm metal supply where they have a brake and have them bend it for you so it looks nice. You're going to spend more money in tools then it would cost to do it right.

 

[N of the rvr]

Call me and give me the dimensions, I’ll make it and send it to you. You’ll have it by the week end to install. (661)549-0606 frank

 

[HOOTER SLED-]

How come the light didn't come with some sort of mounting bracket?

 

[dspracing]

Try starting with something like this - https://www.amazon.com/Sammanlight-...words=LED+Light+Mounts&qid=1615902368&sr=8-15

Ditch the tube clamp portion, you will be left with the two arms that you could bolt to your 1/8" flat bar.

 

[rrrr]

Good excuse buy a Vice you will use for years.

No advice on bending without a vice but please for the love of God, don't be one of those dick's that thinks it's ok to drive around town with led bars on as normal driving lights

I like that. Very cool.

Vice: nope

I don't have many vices since I quit smoking and drinking. But that hasn't affected my ability to use the vise mounted on my workbench.

 

[J DUNN]

Heat that bitch up...throw it in a vise to hammer the 90. Come on maaaan....you're acting like one of those lil girl millenial liberals you're always talking shit about....

So much universal wisdom in just the first 4 words.......

 

[ka0tyk]

step 1... get beer.

 

[Mandelon]

This will bend easier... Sturdy enough for a light.

 

[sonicss31]

You can use the jaws of an adjustable wrench to make bends.

 

[WhatExit?]

So much universal wisdom in just the first 4 words.......

Don't most of Hoots posts start that way?

 

[v6toy4x]

Buy some tools

SWAG 20 TON Press Brake DIY Builder Kit

20 TON Press Brake DIY Builder Kit Press Brake kit comes unassembled, you do the final assembly and welding.Designed to fit the Harbor Freight 20 ton hydraulic press Item # 32879 & 60603.Press brake kit includes an adjustable back stop for accurate and repeatable bends. Max Bending Radius (deg.)...

www.swagoffroad.com

 

[coolchange]

So if a 1x .125 piece steel is on a tread mill traveling 10 mph will it bend?

 

[JayBreww]

step 1... get beer.

Is that what’s taking so long with the bus??


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[JUSTWANNARACE]

Is that what’s taking so long with the bus??


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The bus is big.. I can only imagine how much beer that will take

 

[ka0tyk]

The bus is big.. I can only imagine how much beer that will take

theres room underneath for a few kegs.

 

[JUSTWANNARACE]

theres room underneath for a few kegs.

I was actually thinking the same thing as I typed my reply above!!

 

[ka0tyk]

I was actually thinking the same thing as I typed my reply above!!

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

 

[buck35]

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

Not so fast... We're still watching you. Keep up the good work , it's fascinating!

 

[hallett21]

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

Still watching and waiting for updates [emoji1303]


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[JUSTWANNARACE]

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

Some of us just click on "what's new" which it shows up. I have been watching, just havent posted! So dont let that sub forum detour you! Some of us enjoy that shit!! I usually dont post in the build thread stuff unless I have input or suggestions. What you are doing is out of my realm, hence why I havent commented. But if that's what keeps you posting, I'm willing to be the guy sitting on the sidelines, drinking beer and making comments

 

[buck35]

Some of us just click on "what's new" which it shows up. I have been watching, just havent posted! So dont let that sub forum detour you! Some of us enjoy that shit!! I usually dont post in the build thread stuff unless I have input or suggestions. What you are doing is out of my realm, hence why I havent commented. But if that's what keeps you posting, I'm willing to be the guy sitting on the sidelines, drinking beer and making comments

Me as well! That's a huge undertaking few would have the guts to tackle including myself.

 

[n2otoofast4u]

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

Negative. We’re just waiting for updates!

 

[4Waters]

Also I kinda stopped posting in there as its buried in a sub forum and its pretty evident traffic wise that no one browses outside of the lounge.

Yup, go in there a couple times a week looking for updates

 

[JayBreww]

Yup, go in there a couple times a week looking for updates

The YouTube channel is updated.


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[WhatExit?]

Update...

To make a sharp 90 you may relieve the back/inside of the angle with a cutoff wheel...score it basically. You can also heat with a small propane torch or mapp if you don't have a oxy/ac torch. Anything is better than cold...the outer will get small cracks. To clamp it, use a C-clamp and your tow hitch...sturdy for what you need, and sharper angle than a 2x4.

Call me and give me the dimensions, I’ll make it and send it to you. You’ll have it by the week end to install. (661)549-0606 frank

Thanks to all you guys who posted suggestions. Special thanks to @monkeyswrench for the scoring suggestion and to @N of the rvr for his kind offer to make it for me

* So it turns out I could do this with the tools and stuff I have.
* The ⅛" thick bar actually is ideal and it not hard steel so it's been easy to bend, cut (hacksaw of course) and drill
* I scored the bar with the hacksaw, clamped to my workbench on top of a heavier, thicker piece of steel bar that has a straight edge and bent it quite easily and straight
* I drilled the holes for the light - for the "slotted hole" that allows the light to be adjusted, I drilled 2 holes adjacent to each other and "combined" them

Good thing I have some files as the slotted hole needed some fine tuning and the sharp edges of the holes and hacksaw cuts needed to be cleaned up

Need to locate/mark the mounting holes, drill them, do another test fit then rattle can spray this custom bracket and install it. Then run the wire from the Upfitter switch to the light and add a male Deutsch connector to plug into the light's female Deutsch connector.

Thanks again for all your suggestions. It's going to work just as intended and it will hold up on the truck so while it's not the highest quality work it's the best I could do with what I had and unless I run into any of you guys, no one else will even bother to look closely at it

Scored and bent...

Bent - need to cut left side to length...

Cut and drilled...

Almost done...

 

[LargeOrangeFont]

For the future, I have a 4” vise finger break on hand. It makes stuff like this a cinch. Just drop into your bench vise, measure twice, bend once.

4" Vise Brake

<h1>Grizzly H3243 4" Vise Brake</h1> <h2>The slickest and cheapest way to properly bend sheet metal.</h2> <p>The H3243 4" Vise Brake allows you to bend shapes in metal and then quickly be stashed away when not in use.</p> <p>The dies mount into your vise and are held magnetically. Slide your...

www.grizzly.com