Well, it seems that me being unable to half *** this job, It has taken me a lot of time to complete this rear lightbar and get it fully wired and complete. Today, I bolted the fenders back on since I had them off to take to the painter, but since I decided not to paint them all I did was bolt them back on in gelcoat. I got the lightbar fully fit last night and wanted to do a couple more things this morning before I bolted it on. I had to fabricate the mounting brackets. Thanks to my local weld shop I was able to make some and they will work until I get the polished stainless ones in the mail. All the weld shop did was bend the stainless I drilled the holes and made it all fit. They came out really good. Also, I went ahead and bolted the lightbar to the bottom of the rear crossmember. You can't see the bolts because of the small lip on the opening in the center of the member. Brunners, the makers of the lightbar, they rely on 4 1/4" inch stainless bolts and the thin mounting brackets to support this bar. I built my supports a little different, this bar will withstand anything it is put through.
I had these brackets bent and I was not paying attention and we bent them backwards and there was come type of industrial paint on the stainless and the only way to remove it was to sand it off, if we would have bent them the right way it would have been a simple polish and go. I also got some insight from my brother and we decided to slot the holes that hold it on, this way the bar can be slid off without removing bolts. I used the rear fender bracket bolts to support the bar. I also took a little time and tapered the top so it matched the taper of the bracket. It is a little wider then the fender bracket, but being that I'm getting new stainless ones, I was not all that concerned about them being a little wider.
I went to the truck junk yard today and found a 5 wire weather pack plug that was exactly what the doctor ordered. I then went to the international dealer down the road and bought all new male and female plugs for the weatherpack and built what you see. I wants my wiring to be 100% sealed and also able to be unplugged if the bar needs to come off for some reason. This made it extremely simple and extremely clean.
Tomorrow I have to install my center ground plug, I did get both of the 7 way plugs wired and installed, the one on the left is for the standard plug, the one on the far right has hot wires for lift axles, strobe lights, load lights and so on. Not all of the wires in that 7 way are in use right now.
