 | Home > Td5 > Light bar installed in my TD5 |
 
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| MC84 Member Since: 23 May 2016 Location: Near Bristol Posts: 360   
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I�ve just fitted a light bar to my Defender 90. I didn�t want to roof mount it and played with the idea of fixing it to the bumper but didn�t want to spoil the line of the truck. HuffHuff has mounted his within his grille so I cannot take any credit for having the idea but thought it might be interesting to document what I did, for those interested.
As I wanted to mount it in the front grill there is a width restriction. 68cm�s was as much as I could get in so the biggest one under that, that I could find was 21�. Having a look around on the net and weighing up price against quality I choose this one: http://www.flatdoguk.com/21%22%2Dfd%2Dpred...bar%7E1411 I actually bought it through �Paddocks� as they did a price match. As it needed to be as recessed as possible so it wouldn�t stick out too much from the grill I needed to cut some on the heat-sink fins from the bar. I�m sure I have invalidated any warrantee I had!  Click image to enlarge Click image to enlarge Once this was trimmed I offered it up to the position I wanted which is as high as I can go in the grille. From this location I took rough measurements of the brackets I needed to make to support the bar. I wanted to use holes already there and found a pair of bolts either side holding the radiator/front panel in place. My truck has enough holes without making too many more! These are what I came up with: Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge I had previously trimmed a new grille I bought for the project as you can see. Once it was cut it all went a bit limp so I have reinforced it with brass bars (3mm) and bonded them to the plastic. The bonding isn�t too neat but only I will know as you won�t see it when fitted! Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Two of the larger brackets fitted Click image to enlarge Click image to enlarge Click image to enlarge This is the finished install. The bar is slightly proud of the grille but I�m happy with it. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge A few weeks earlier I fitted an upgrade loom for my headlights so have wired into that to fire up the bar when on full beam. It�s very bright! Thanks again to HuffHuff for the idea  Mike
Hard Top 90 TD5 2001 Ford 100e 1959 www.youtube.com/mikemakesit |
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20th Jan 2017 7:17pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801 
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Looks neat
I've got mine behind the lower grille. As you mention it doesn't upset the lines of the defender 
Click image to enlarge 2002 90 Td5 Station Wagon 1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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20th Jan 2017 7:23pm |
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| Nick666 Member Since: 23 Mar 2016 Location: Somerset / Dorset borders! Posts: 81 
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Those look really very neat, nice work!
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21st Jan 2017 11:54pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 1:08am |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6772  
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Grafty, Any pics of how you mounted yours? Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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22nd Jan 2017 1:41am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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I don't but basically it's bolted through the grille.... 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 1:52am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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Hang on I'll pop out and take a picture 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 1:53am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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Click image to enlarge Click image to enlarge 2002 90 Td5 Station Wagon 1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 1:55am |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6772
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I like that
might have to nic that idea but with two seperate lights (one for each side of the grille) does the grille have any negative effects on the light output? And do you have any pics of the light output from inside the cab ? Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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22nd Jan 2017 2:36am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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I haven't got any pictures from in the cab but will try and get some tomorrow night.
I have also mounted 2 lights individually on my 110. Slightly different approach though as it had aircon. I'm sure the grille does reduce light output but not enough to worry about 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 2:49am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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Click image to enlarge 2002 90 Td5 Station Wagon 1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 2:53am |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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Click image to enlarge 2002 90 Td5 Station Wagon 1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 2:55am |
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there's only a hole for the starting handle 
| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4801
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Is there enough room between the radiator and the grille to mount something? 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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22nd Jan 2017 9:57am |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6772
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Thanks Grafty
Greeni couldn't you change the grille surround for a later one? It would get rid of the unused bonnet lock hole at the same time. Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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22nd Jan 2017 2:26pm |
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