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MC84

Member Since: 23 May 2016
Location: Near Bristol
Posts: 341

Light bar installed in my TD5

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

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

Two of the larger brackets fitted

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

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

20th Jan 2017 7:17pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

20th Jan 2017 7:23pm

Nick666

Member Since: 23 Mar 2016
Location: Somerset / Dorset borders!
Posts: 81

1986 Defender 90 2.5 n/a Diesel SW Yellow

Those look really very neat, nice work!

21st Jan 2017 11:54pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

22nd Jan 2017 1:08am

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Grafty, Any pics of how you mounted yours? Ray
My build thread
http://www.defender2.net/forum/topic17615.html

22nd Jan 2017 1:41am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

22nd Jan 2017 1:52am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

22nd Jan 2017 1:53am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

Click image to enlarge

22nd Jan 2017 1:55am

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

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

22nd Jan 2017 2:36am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

22nd Jan 2017 2:49am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

22nd Jan 2017 2:53am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

22nd Jan 2017 2:55am

GREENI

Member Since: 22 Aug 2010
Location: staffs
Posts: 10359

As much as I love and use my RI lights, I don't want them spoiling the 90, through the grille would be perfect.

But even there I can't do it

there's only a hole for the starting handle

Click image to enlarge

22nd Jan 2017 9:12am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

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

22nd Jan 2017 9:57am

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

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

22nd Jan 2017 2:26pm

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