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Old 04-06-2014, 01:09 AM   #1
LipsFan3021
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Rally Light Bar Project

Hi all, This is my first post here. I'm starting a long dreamed project to put a rally style light bar on my 2007 ZX5.

I thought I'd start with the design workup I've done and pics I've found of others. Yes I know Rallyinovations makes a bar but it doesn't serve my needs. Once done if all goes well I would like to work up a kit for anyone interested in this mod.

For my bar I will be using 1" square tubing as it is cheap strong and provides a good solid mount for lights without need for mounting tabs on round tubing. This will be bolted to L brackets themselves bolted to the exposed bumber bar. This way the whole thing can be removed for maintaince exc. I will be working with a local welder to do the fabricating and then will paint it myself. I will also mount the bar, lights and do all wiring myself.

I plan to use all Hella lights and have the following,

500 fog to replace factory fogs (I bought base model blanks for fog openings to remove factory lights and will be using factory wiring via an h11 plug wired to 500 fogs allowing factory switch to work these lights)

500ff driving for low beam driving light wiried to factory low beams

700ff driving for high beam driving wiried to factory high beam

Both driving lights will be switched to allow headlight use without aux lights being on.

These first pics are my sketches of bar design and mesurments from my car.

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This second group are pics I found online.

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I will post more as project developes. I hope to be done within 1 month.


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Old 04-06-2014, 01:27 AM   #2
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Awesome. I'd definitely be interested in a kit if you get it figured out nice. Here in MN we have to have a license plate in the front, do you in OH? I keep thinking if I get a light bar i'll get stopped for obstructing the plate
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Old 04-06-2014, 01:53 AM   #3
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yes we are supposed to have a front plate but I have never used mine as the hellas I currently have are mounted in the plate holes. I am worried cops wont like new light bar so it will be set up to mount a plate if needed. I've been stopped in the past for yellow headlights twice by shp and neither said anything about no front plate though. after all the rich guys in vets Porsche Ferraris and the like don't even have a place to mount them so if they don't why shoud we, but that said that's the cops call
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Old 04-06-2014, 04:06 AM   #4
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Well, it's the law in Ohio, but it is also up to the officer's discretion as to whether you get a ticket for it or not. There are some townships locally as you know that are a bit more picky about this. I went 6 years without a front license plate on my Focus and never had a problem. I went for 1 week without a plate on my Miata and got popped for it lol. There was a member on here that did a light bar awhile back but I can't remember who it was. I am sure if you did a search on the subject, you can find additional information on it. I know SVT_BMXer and mlbbaseball had light bars on their Focus at one point and time. Perhaps look up their names in advanced search and you can see their results.
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Old 04-08-2014, 11:53 PM   #5
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Lbp

Rain out this week in Cincy. Try to hit up welder next week. More updates to come!
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Old 04-09-2014, 01:59 AM   #6
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I definitely wanna see pictures as you make progress! My next project is a light bar that will serve as header protection as well for my SVT. A google search can only do so much..
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Old 04-09-2014, 04:09 PM   #7
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Quote:
Originally Posted by LipsFan3021 View Post
Rain out this week in Cincy. Try to hit up welder next week. More updates to come!
I hear you on this. I am still waiting for a nice weekend to install my roll bar for my Miata.
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Old 04-16-2014, 02:20 AM   #8
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Lbp

Well once again I was rained out. Stay tuned.
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Old 04-21-2014, 06:22 PM   #9
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Made it to the welder this week finally. He is starting first mockup and will be test fitting asap. Photos and update to come.
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Old 07-07-2014, 05:17 PM   #10
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Update

Well its been awhile between the welders backlog and some vacation time here where its at. Went to welder today bar is done and test fitted last welding being done this week. Next two weeks should see paint, fitting to car and light install done. Many photos to come over next two weeks
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