Help with custom install

[BMRbrnSNRbrd]

So here's what I'm doing to the lower bumper area:

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_140740_zpscae97258.jpg

Here's the progress I've made so far:

Lower bumper opening without insert:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_143213_zps9ee48a87.jpg

Cut out the vertical supports:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_143938_zps03c8085e.jpg

This is just to show how much of the space the bar will fill. The bar is just sitting on the lower bumper:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_144135_zpsb26cb448.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_144140_zpsf769f67b.jpg

As you can kind of see here, the lower insert not only curves up but curves in as well:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_145220_zps2ae109b8.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_145227_zps62b24988.jpg

My issue here is that, obviously, the bar does not curve in any way. So here is the only option I can come up with. I would cut along the red line you see here:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130301_145227edit_zps9ff56b90.jpg

Now, I could either leave it wide open and the bar would just sit back a bit in the center OR I could fill this area with some sort of black mesh. I like the mesh idea, but then again I don't because the upper grill is not a mesh.

Thoughts?

[ramthis9501]

I have metal billet inserts that you could just have and see if you could install them somehow. They would need to be painted to match, but I think they'd go good with the rest.

[deadhead_94p]

The billet would look better, then I'd make the cut before going with the mesh.

[myoung84]

I think I would just cut out the red portion and leave it at that. With a little tint on light bar, I think it will all blend it great.

If you do the mesh or billet options, you'll have to make sure it's curved right or it might look off...

[BMRbrnSNRbrd]

If you do the mesh or billet options, you'll have to make sure it's curved right or it might look off...

That's my concern as well. I don't know anybody who is good enough with metal to make it bend that way. I would also have to fab up a way to mount the billet insert.

I'm thinking of going to my tint guy and seeing if he can just lay a light layer of tint on the lense. The cheapest option with Lamin-x will leave me with over 50' of tint left but with a max width of 5", it wouldn't have much use.

[0212353]

how deep is the led bar?

can you just cut a part out of the insert and the bar fills it? And yeah, you'll have 1" at the bottom and its flush at the top? that kind of deal?

[myoung84]

Didn't think about window tint. Would that hold up to the heat?

[0212353]

side note...........kinda surprised with this mod. Interesting addition to the truck David!

[Matt]

tinting plastic is tricky bc if you decide you don't like it or it fades real easy or anything makes getting the adhesive off that plastic extremely difficult i would cut the red line and then go from there .. if you don't like it you could always add mesh to it later ...

[DoubleTakeDodge]

I'm not big on the mesh idea just because it wouldn't match. BUT.... Do the mesh and get a nice looking black mesh grille? Otherwise I would just make the cut and leave it be

[nightmatt]

honestly i wouldnt worry about doing mesh or billet. I think it will look good without it. but if you do decide to add it I may be able to help with making it. lucky for you I work with metal fabrication all day ever day. if not me, I know a few guys from work who probably could.

[BMRbrnSNRbrd]

how deep is the led bar?

can you just cut a part out of the insert and the bar fills it? And yeah, you'll have 1" at the bottom and its flush at the top? that kind of deal?

Haven't measured, but it's probably 3 or more inches deep. I'm not sure what you mean by the part I bolded.

Didn't think about window tint. Would that hold up to the heat?

I'm not sure. I'm sure it gets hot, but how hot? I thought about asking my tint guy that.

side note...........kinda surprised with this mod. Interesting addition to the truck David!

Thanks bud. I just figured it would be different.

tinting plastic is tricky bc if you decide you don't like it or it fades real easy or anything makes getting the adhesive off that plastic extremely difficult i would cut the red line and then go from there .. if you don't like it you could always add mesh to it later ...

I didn't know about that. I really wanted to do Lamin-x but it's $50 for a 4"x50' roll.

I'm not big on the mesh idea just because it wouldn't match. BUT.... Do the mesh and get a nice looking black mesh grille? Otherwise I would just make the cut and leave it be

The only mesh uppers I've found are either cheap crap or horribly expensive (like $300+).

honestly i wouldnt worry about doing mesh or billet. I think it will look good without it. but if you do decide to add it I may be able to help with making it. lucky for you I work with metal fabrication all day ever day. if not me, I know a few guys from work who probably could.

I'll definitely keep that in mind bud...as a matter of fact. I'm going to text you now.

[0212353]

I mean that if you centered the bar, then put the insert over that, you'll have......an underbite or whatever - but it would probably look the cleanest....i think?

[BMRbrnSNRbrd]

Oh, yeah, I agree. I think I'll just mount it completely centered horizontally and vertically and then cut the plastic piece as little as possible.

[(S.M.R) 101]

Gunna be sick man!

[BMRbrnSNRbrd]

I had to take a couple days off from work so I'm getting some time to toy with this. I have the dash apart and have run the power wire for the relay as well as finding a good hiding spot for the relay. I should get the rest of harness completed tomorrow and then start fabbing up the mounts for the bar.

[(S.M.R) 101]

Awesome Dave... I'm pretty stoked to see this all installed man.

[0212353]

rockin'

[BMRbrnSNRbrd]

Alright, the wiring is completely done. I have to figure out what I'm going to do for tinting the lexan because what I thought would work, won't. Also, tomorrow will be completely devoted to fabbing the mounting brackets...which is going to suck.

[0212353]

oh thats the fun part!!!

[Matt]

lol yep

[BMRbrnSNRbrd]

Bought the stuff to make the brackets and tint the lexan tonight.

[(S.M.R) 101]

Where you going to mount the toggle switch?

[BMRbrnSNRbrd]

You mean 'where did you mount the toggle?'

[(S.M.R) 101]

You say potato I say potato..... Where is the fucking thing mounted.... :D

[DoubleTakeDodge]

You say potato I say potato..... Where is the fucking thing mounted.... :D

Hahaha I think that saying is more effective when spoken out loud lol

[(S.M.R) 101]

I'm sure Dave gets the just of the saying :)

[myoung84]

Lol

[0212353]

well? how goes it?

[(S.M.R) 101]

I just seen something bad ass with it!!! the light bar that is

[0212353]

out with it!

[0212353]

pic hoarder.

[BMRbrnSNRbrd]

Uploading now.

[BMRbrnSNRbrd]

Alright, time to all but finish this up:

Dash torn out...I did this while waiting for my class to start one night:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011310_zps3be59744.jpg

Here's the simple switch I used and it's placement in the cubby hole on the left side of the main center stack. It's off centered for a reason so that I can easily get to it with my hand:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011311_zps710ecc1e.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011313_zps2e80697b.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011312_zps29f23bb7.jpg

Switch wiring:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011314_zps98e5325a.jpg

Time to black out this light bar so that it looks like it belongs on my truck:

This is available at Home Depot for $20. It's not permanent, so if I want to remove it or change it out later, it's very easy. I heard about this from someone who used it on a lexan rear truck window for a truck that had a cage running through the back window:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011315_zps8205fd9c.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011316_zps86ca94f1.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011317_zpseb7f3da5.jpg

I ended up cutting this down to the exact size of the lexan:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011318_zpsefa7441e.jpg

All those little screws that hold the outer trim down (which holds the lexan down) were removed and painted with black, high heat enamel:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011319_zps4637b615.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011320_zpsf9a8e677.jpg

Blacked out light bar completed and re-assembled:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011321_zps546a112c.jpg

[BMRbrnSNRbrd]

Now fabbing up the mounts. I used some very thick metal brackets from Home Depot and then bent and cut them to work for me. They were also painted with the black enamel, but I forgot to take a pick of them after paint:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011322_zps5d182c3b.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011323_zpsb989e34c.jpg

Done with installation. I love how it's almost invisible even without the trim piece on:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011324_zps45f465e0.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011325_zpsd3c19cf4.jpg

Lit up:
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011326_zpsdaf436f0.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011331_zpsf22682e5.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011329_zps21527222.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011330_zps830e50e0.jpg
http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/03011327_zpsf0977074.jpg

I might be able to finish up the trim piece this weekend.

[myoung84]

Damn David! That looks bad ass! I like how you even painted the screws.

[BMRbrnSNRbrd]

Thanks Morgan. My biggest thanks goes to you. You made wiring this up correctly with a relay and in-line fuse sound like no big deal. Thank you very much.

[myoung84]

Glad I could help!

[Okiespaniels]

Looks like a prehistoric land shark...I know, non existent...but that was my first thought.

[0212353]

spiffy!

did ya take it out at night at fire that biotch up yet?

[BMRbrnSNRbrd]

Yeah, the brackets need to be manipulated just a bit more to pull the majority of the light down...I'm looking in trees right now

[0212353]

ahhh!

[DoubleTakeDodge]

Nice!! Looks good man!

[nightmatt]

damn dude, very nice job, looks awesome I love it

[BMRbrnSNRbrd]

Thanks fellas.

[BMRbrnSNRbrd]

Well I've pulled the bar back out, removed the tint, modified the brackets to work a bit better and stopped. As for right now, the bar will stay out until next week. I found a local company that builds signs and displays and can order factory produced tinted or smoked lexan. Basically it is tinted as part of the production process and not just a layer of film put over the product. I should have a piece cut to fit by Wednesday of next week.

[0212353]

spiffy man, that should be better!

[myoung84]

Is it possible to paint it like mine, with the overlay black and the circle reflectors left chrome? I like the way that looks on my truck. I haven't seen a close up of your bar to see if that's possible.

[BMRbrnSNRbrd]

I'm sure it is possible but still wouldn't work for the look I'm going for...and it sounds like a lot of work.

[Matt]

Is it possible to paint it like mine, with the overlay black and the circle reflectors left chrome? I like the way that looks on my truck. I haven't seen a close up of your bar to see if that's possible.

yes it's possible i've seen one done that way but i think david wants it completely dark ...

i think the best solution is to put something over the opening of the insert it's going to hide it while not limiting the output of the light unlike any of the tinting and such is going to i'm afraid .. unless you do it like the old school black out headlight covers and make it removable .. or even better use an actuator to flip open a panel or something lol

[BMRbrnSNRbrd]

I'll see how this smoked lexan works and go from there.

[BMRbrnSNRbrd]

Just a small update:

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130319_144104_zps2e410a1a.jpg

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130319_151818_zpsdae03517.jpg

As you can see, the new piece is just a little darker than the original.

That is all. The bar is re-installed but I won't have a chance to check light output until it gets dark. I also have to figure out the best, clean way to cut out my insert to finish everything.

[(S.M.R) 101]

Awesome man!

[0212353]

well thats slick

[myoung84]

That's going to look sweet!

[BMRbrnSNRbrd]

I got a chance to check out the light output this morning on the way to work...WOWZA!

[myoung84]

Where's the pics!?!?

[Matt]

exactly lol i want to see it !!

[BMRbrnSNRbrd]

I went and bought an pneumatic body saw tonight and started cutting the insert. I'm going to wait for more pics until the install is complete. Now I'm debating smoothing and painting what is left to match the truck. Thoughts?

[(S.M.R) 101]

I would want to see it as is installed before I comment about the paint.

[BMRbrnSNRbrd]

Cool. I should finish cutting it out tomorrow evening. Then I'll lightly sand the edges and finish that with a torch lighter to give it a smooth stock look.

[(S.M.R) 101]

Sweet dude, Can't wait to see the pictures

[myoung84]

I would want to see it as is installed before I comment about the paint.

Me too. I think leaving it black would look good and match the black grille. Also painting it might make the light bar stick out more, it would blend in better if black.

[BMRbrnSNRbrd]

Me too. I think leaving it black would look good and match the black grille. Also painting it might make the light bar stick out more, it would blend in better if black.

Damn good point. It is settled then, it will stay black and just get a coat of PD.

[BMRbrnSNRbrd]

Ok, I'm still not completely finished. I still need to sand the rough edges and then use the torch to really smooth them out. I decided you guys deserved some "finished" pictures:

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130322_171056_zpsa3521ed9.jpg

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130322_171117_zps866c80cc.jpg

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130322_171028_zps9856d55c.jpg

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130322_171039_zps986e0557.jpg

http://i269.photobucket.com/albums/jj60/BMRbrnSNRbrd/2010%20Dodge%20Ram/20130322_171045_zps0b9cd744.jpg

I'm sorry about the shitty cell pics, but I'll get better pictures when it warms up again and I can wash the truck. I know the light bar isn't as hidden as before, but it is definitely usable now. The light output before made it a joke.

So, anyone willing to give me honest feedback?

[(S.M.R) 101]

Honest? I friggin love it dude. It sits in there perfect and looks bad ass.

I think it woul take a double look to notice it, so it's got a stealth look to it. Tasteful and well done buddy

[DoubleTakeDodge]

It's very well done in my opinion. Looks amazing man. Good job!

[0212353]

spiffy