4.2 Rav4 Light Bar - prototype run - Toyota RAV4 Forums
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#1 (permalink) Old 02-22-2012, 02:01 PM
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4.2 Rav4 Light Bar - prototype run

Just gauging some interest here. Based on the last few threads there has been some:

Cool custom parts for RAV?
Bumper Light Bar

I have spent some time designing and tearing apart the front of my Rav to come up with a bolt on lightbar that will not require any cutting or modification to install. It should be installed with the bumper removed, but I have designed it in a way that it may be able to be installed with the bumper on the Rav...it will just take a bit of persuasion. I will determine that once I have the final prototype for fitment. For now I have been cutting out some brackets and doing some test fitting.



This is what the light bar will look like. There are still a few things I will be tweaking during the fitment process.


The lights pictured are Hella 500/500FF series: Susquehanna MotorSports - Auto Performance Product

The reason I am building a light bar as opposed to a bull bar, is that I never plan on using my Rav to nudge another vehicle...and the bull bar actually reduces your ground clearance/entry angle at the front of the Rav. I just wanted more lighting and this light bar will allow for exactly that without any compromise. It will allow for four lights up to Ø7-3/4".

The mild steel frame is CNC cut, TIG welded and will be coated with a high quality paint. I've built lots of parts in the past but usually in one time group buy formats until I move onto the next product to develop. Some of the parts I have produced have been resold for more than the original owner paid for them, just due to it being a rare and limited part! So don't sit on your hands if you are considering buying one! The intro group buy price for the light bar will be $225USD + shipping (estimate $40~ish).

This light bar is 100% Canadian designed and manufactured with the material coming from a nearby Canadian steel mill.

Anyone interested? I'm only going to begin a build if there are at least 10 people interested.


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#2 (permalink) Old 02-22-2012, 03:13 PM
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sweet. the light must be great now!

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#3 (permalink) Old 02-23-2012, 04:16 AM
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That's some beautiful metalwork. Shipping to the UK and are the lamps included in the price?
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#4 (permalink) Old 02-23-2012, 09:57 AM
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Conrad you know I will be getting one

1. How does it mount( maybe a cad drawing to illustrate(

2. How does one take the bumper off?
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#5 (permalink) Old 02-23-2012, 02:16 PM
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Originally Posted by Joylove View Post
That's some beautiful metalwork. Shipping to the UK and are the lamps included in the price?
Thanks! The top bracket is the first prototype, the one below had some tweaks to it (based on the fitment of the top bracket), I will have 2-3 more prototypes I believe before I am 100% satisfied. The bar that the lights mount to will probably only need to be built once as the design of that is quite simple.

The lights will add significant bulkiness to the packaging, so I have not included the lights so that way the owner can choose what lights they want to use. FYI Hella 500FF aren't the best lights out there, but they are the best bang/buck. A set of four Hella 500FF lamps are around $150~ish.

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Conrad you know I will be getting one

1. How does it mount( maybe a cad drawing to illustrate(

2. How does one take the bumper off?
Cool! Well lets hope there is enough interest and we can get this off the ground!

1. I didn't model the crash bar or bumper to save time, I just took measurements and designed off that, however here is an idea of how it will go on.




It clamps to the existing crash bar seen here in Sensei's post:
Bumper Light Bar

2. I found a procedure on this forum how to do it...but there were some glaring issues on how to do it. Lots of "leap of faith" by tearing off clips... lol. When doing it I found ways to remove pieces like how Toyota or a bodyshop would actually do it, it's actually quite easy but may be intimidating to most their first time. Now that I've done it I could probably have the entire front of the Rav removed in 20 minutes only using a phillips screw driver, narrow slotted screw driver and a 10mm socket. When selling this light bar I would do an actual procedure on the proper way to remove everything if one wanted to.

All the mounting hardware is behind the bumper so there is no way for someone to just walk up and remove a few bolts and take it...some lights on the market come with (or you can buy extra) security hardware to make it difficult for someone to remove the actual light housing too. So the light bar is designed to be theft proof, it makes the install a bit trickier but I'd rather make the one time install a bit tougher than have someone remove a few easy access bolts because of a poor design and take a few hundred dollars in lights.

The gist of the design is done, just a few little tweaks with some of the brackets. One being the bracket that the lightbar is mounted to will be a bit longer to allow for a bit more room between the bumper and the back of the housing of the light. But how the light bar is installed and what you see is virtually what it will be. I should be finalizing the design this weekend. If there are enough interested people then I'll begin producing them and ordering the appropriate packaging and materials.


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#6 (permalink) Old 02-23-2012, 04:23 PM
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I'm very interested in this and am glad you're going this route. One small design question I had relates to the fact that the light bar extends in front of the bumper (feel free to shoot me down).
1) Have you thought about running the brackets a little higher so the bar/lights sit atop the bumper? My mind would be a little more at ease if the light bar was above the bumper and extended only as far as the bumper?
2) Do you think the light mounted on the lightbar would be more likely to interfere with the headlights if mounted higher? I wonder if there's even enough room to squeeze lights up there?

Again, I'm really excited to see you move forward with this and you can pencil me if things continue to progress.

By the way, I've been lurking on this board ever since I got my Rav but just recently made an account. Thanks to all the great members like Conrad I have learned enough to actually post meaningful content. Stuff like this is what makes communities like R4W awesome.

Check my Garage to see mods and add-ons

Last edited by Silver05; 02-29-2012 at 01:27 PM.
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#7 (permalink) Old 02-24-2012, 11:47 AM
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Originally Posted by Silver05 View Post
I'm very interested in this and am glad you're going this route. One small design question I had relates to the fact that the light bar extends in front of the bumper (feel free to shoot me down).
1) Have you thought about running the brackets a little higher so the bar/lights sit atop the bumper? My mind would be a little more at ease if the light bar was above the bumper and extended only as far as the bumper?
2) Do you think the light mounted on the lightbar would be more likely to interfere with the headlights if mounted higher? I wonder if there's even enough room to squeeze lights up there?

Again, I'm really excited to see you move forward with this and you can pencil me if things continue to progress.

By the way, I've been lurking on this board ever since I got my Rav but just recently made an account. Thanks to all the great members like Conrad I have learned enough to actually post meaningful content. Stuff like this is what makes communities like R4W awesome.
I have thought about moving the lights higher in the initial design layout, however I didn't due to the housings shrouding the OEM headlights slightly and the chance for more prominent vibration. Also the location in the center of the bumper is the best compromised location to either install aftermarket fogs or driving lights. Typically you want driving lights inline with the headlights and the fog lights as low as possible, in this case the light bar allows for a compromise of both. Allowing someone to run both in the same area without overly compromising one set of lights over another.

I've been on automotive forums for at least 10 years, I have been a moderator on a few and I still moderate the Engineering/Fab forum on CelicaTech when I have time. In all honesty I just try and help out people where I can, because I always soak up information where I can too. Sharing information will only benefit us all!


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#8 (permalink) Old 02-24-2012, 03:20 PM
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I like the current design because as far as I can tell it is designed to require no modification at all to the stock bumper. This is a very good thing. I would not be willing to drill cut or modify my front bumper in any significant way, in fact I am still pissed off about having to mount a Virginia front plate when I moved away from Arizona.

Edit for after thoughts
In fact I am also envisioning a similar but beefed up bracket exiting through the lower bumper hole acting a a serious recovery point. But maybe the stock ones are better than they look and so far I have not needed a recovery point on the front at all. I am thinking just one of the brackets that clamp around the real steel bumper would be more than adequate to hold my 2000L 6led light. I have even been considering a suction cup based gopro camera mount to hold the light as it is about that size and weight.

On the road in my Rav4 since February, Traveling, Volunteering, Camping and also enjoying beer bikes and bacon. Check out the blog www.servicedriven.org
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#9 (permalink) Old 02-24-2012, 06:06 PM
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Conrad
Will the steel you use be able to be rhino lined, and the bolts that you use will they be galvanized or something to prevent rusting like most aftermarket ones do (hence why I want to rhino line one )
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#10 (permalink) Old 02-25-2012, 03:49 AM
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I like the current design because as far as I can tell it is designed to require no modification at all to the stock bumper. This is a very good thing. I would not be willing to drill cut or modify my front bumper in any significant way, in fact I am still pissed off about having to mount a Virginia front plate when I moved away from Arizona.

Edit for after thoughts
In fact I am also envisioning a similar but beefed up bracket exiting through the lower bumper hole acting a a serious recovery point. But maybe the stock ones are better than they look and so far I have not needed a recovery point on the front at all. I am thinking just one of the brackets that clamp around the real steel bumper would be more than adequate to hold my 2000L 6led light. I have even been considering a suction cup based gopro camera mount to hold the light as it is about that size and weight.
Yes that was one of the main criteria, absolutely zero cutting or hacking up of the Rav.

Not sure if I would want any major stress on the crash bar (except when in an actual collision)...but I have not looked at the OEM recovery point as a weakness, or if it needs to be beefed up.

Quote:
Originally Posted by crazyypilot View Post
Conrad
Will the steel you use be able to be rhino lined, and the bolts that you use will they be galvanized or something to prevent rusting like most aftermarket ones do (hence why I want to rhino line one )
Actually I have produced a lot of underbody braces in the past and I have used rockerguard paint that works really really well. This will be coated with the same product. The hardware will be galvanized at a minimum, yes.


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