China Factory for SQUARE BAR for Angola Factory

Plans: https://www.4diyers.com/resources/metalwork/grilllightbar.php
Basic rust repair: https://www.youtube.com/watch?v=H44w5XvKuk0
Light bar review: https://www.youtube.com/watch?v=_nWuW8FTFK8

Video tutorial on how to fabricate a hidden grill mount for a light bar. This is a great project for beginner welders to help perfect your metal fabricating skills. This particular light bar was designed for a Ford Ranger and will possible fit the Mazda B Series as they share the same platform. The particular light bar used in this video is a 22” 5D LED light bar made by Auxbeam. Blueprints for these light bar plans are available on my website as a pdf file which can be easily printed off. This particular vehicle I am working on is a 1998 Ford Ranger.

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Tools/Supplies Needed:
-welder
-grinder with disks
-square
-scriber
-welding equipment
-wire brush
-tape measure
-nutcerts & nutcert tool

Procedure:
-disassembling the front of the vehicle to determine where the mount can be fastened to
-material was purchased from a local steel supplier
-fabricating the radiator mount first, mark out the rough dimensions with the paint marker, then mark the exact dimension with a scriber and square
-using an angle grinder with cutting disk, cut the material to size
-it’s best to use a cut off saw for squareness, but not everyone has one
-considering this is a thicker material, edges will need to be chamfers to help with welding penetration and reduce heat distortion
-clean up welded areas to remove any surface impurities which may affect the welding process
-for this I am using a flux core mig welder
-if you have a surface to clamp down the parts you are welding, that does make it much easier so the parts don’t move or distort when welding
-use a chipping hammer and wire brush to remove the slag and clean the area
-a full weld can be applied to each
-now the welds can be cleaned up, removing the slag
-if you find a spot where the weld maybe a little high, a grinding disk or flap wheel can be used to knock off the high spots
-for the radiator mount install, I used clamps to hold it into place, just tight enough so I can center everything up and mark out the holes to be drilled
-use common reference points which were symmetrical to the truck to keep everything as accurate as possible
-to drill the holes for the mount, I used a transfer punch first for hole layout on the top bolts. A transfer punch is a type of punch that is sized accordingly to an existing drill hole and has a center point
-all the tubing was cut to size, the pieces going into the grill will be slightly longer and adjusted one everything is in place
-in order to get those square cuts, I used a paint marker, installed a gear clamp on the pipe, and then follows around the edge with the scriber
-tack weld the bents in place first, you can use clamps to hold everything in place or welding magnets
-after everything is test fitted, the tubing can now be solid welded
-to smooth out those welds, use the angle grinder and flap wheel just like before
-the welded areas can be blended using a file
-assemble the light bar so we can have exact measurements
-cut it to size and square it up if need be
-drill the holes for the light bar mounting and I am also drilling three other holes for plug welds
-welded areas as needed
-square up the tubing which mounts to the radiator support
-for fastening pointed, I have welded in nuts to the tubing
-wipe the pieces down with a wax and grease remover so there will be no contaminants when sanding
-use abrasive pads and then finished up with 220 grit sandpaper before the primer stage
-give the pieces another wipe down using a wax and grease remover
-a high filler primer can be used to hide any surface imperfections
-pick a color and finish of your choice
-once the paint has dried, the bracket can now be installed on the truck
-use fasteners with flat washer and medium grade threadlocker
-the plastic diffuser will need to be noticed out, so put that into place, mark out the openings, and use a hot knife to cut the areas
-once everything fits correctly, clean up those cuts with a file
-snap the diffuser back into place and then reinstall the grill
-now install the light bar bracket to the radiator mount

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