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Decided to add some ditch lights to the Bronco. My original plan was to mount a pair of KC Rally 400's directly to the accessory mounting points in front of the A-pillars. Unfortunately, on the passenger side, the light ended up interfering with the antenna.
I started looking at some of the aftermarket ditch-light brackets, but decided to make my own for a few reasons.
First, I just couldn't justify spending $70–$90 for a couple of brackets. Sick of the Bronco Tax.
Second, I wasn't really crazy about the look of most of the ones I found. Most seem to mount to the two factory holes, then step up an inch or so with the mounting hardware underneath. Just my personal preference, but I thought they looked a little unfinished. And any time you have something sticking up into the airflow, it seems like another opportunity for wind noise or whistling.
Third, at the end of the day, I just enjoy making my own stuff and being able to design it exactly the way I want it to look.
So I came up with this quick design. I went to my local metal supplier and bought a piece of 1" wide x 3/8" thick aluminum flat bar. I bought 8" of material, it ended up costing me just over $8 out the door.
After cutting the ends to the shape I wanted, I split most of the width of the bar on the bandsaw, then cleaned up everything with some files and a Dremel. I drilled the two mounting holes and tapped a 3/8" hole for the light. I used some stainless hardware I already had laying around.
The end result is pretty much exactly what I was looking for: simple and clean, with no unnecessary hardware or brackets sticking up into the airflow.
The lights still retain full adjustability both up and down and left to right, so I didn't give up any functionality compared with a conventional bracket.
For now, I just painted the brackets. At some point I'll probably pull them off powder coat them, but for now the paint will do.
All in all, this was probably about a half-day project, and for roughly $8 in material, I think it was well worth the time. Just wanted to share in case anyone else is considering ditch lights and likes the idea of making their own brackets.
I started looking at some of the aftermarket ditch-light brackets, but decided to make my own for a few reasons.
First, I just couldn't justify spending $70–$90 for a couple of brackets. Sick of the Bronco Tax.
Second, I wasn't really crazy about the look of most of the ones I found. Most seem to mount to the two factory holes, then step up an inch or so with the mounting hardware underneath. Just my personal preference, but I thought they looked a little unfinished. And any time you have something sticking up into the airflow, it seems like another opportunity for wind noise or whistling.
Third, at the end of the day, I just enjoy making my own stuff and being able to design it exactly the way I want it to look.
So I came up with this quick design. I went to my local metal supplier and bought a piece of 1" wide x 3/8" thick aluminum flat bar. I bought 8" of material, it ended up costing me just over $8 out the door.
After cutting the ends to the shape I wanted, I split most of the width of the bar on the bandsaw, then cleaned up everything with some files and a Dremel. I drilled the two mounting holes and tapped a 3/8" hole for the light. I used some stainless hardware I already had laying around.
The end result is pretty much exactly what I was looking for: simple and clean, with no unnecessary hardware or brackets sticking up into the airflow.
The lights still retain full adjustability both up and down and left to right, so I didn't give up any functionality compared with a conventional bracket.
For now, I just painted the brackets. At some point I'll probably pull them off powder coat them, but for now the paint will do.
All in all, this was probably about a half-day project, and for roughly $8 in material, I think it was well worth the time. Just wanted to share in case anyone else is considering ditch lights and likes the idea of making their own brackets.
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