OK. I finally found a little "free" time. I'm posting this mainly for the use of the hard drive magnets. Not much else is very creative, and I didn't even wire it up yet. Anybody got any spare time? I need more.
I found a piece of 1/4" aluminum, 16 X 3 inches in my scrap pile. It had a short ring welded to the side, so I left it on. I don't know what I'll do with it, but I'm sure it will be important one day.
I had to bore two big holes in the bar so I could use it at the top of my ROPS. The ROPS has two big bolt heads spaced a little over 5" apart. I scratched my head for a while and decided to use the 1 3/8" spade bit that was calling my name. Go ahead and laugh, but this bit is a little better than the basic flat stamped ones. Anyway, with a little oil and predrilling the center hole, it worked just fine. Yes, I used the drill press and clamped the work down.
Next I selected three similar magnets from the small pile I got at work. Lucky for me I bumped into the hard drive party one day, where they had taken apart about thirty computer hard drives. The magnets are very strong, and have mounting holes already drilled on them. Find a few friends with dead hard drives and take them apart. Newer ones pretty much all have similar sized magnets, since they're just a commodity now.
I drilled and tapped the plate for 8-32 screws to hold the magnets. The magnets are only about 1/8" thick. I only had round head machine screws in the bin, so I had to grind the heads lower after I installed them.
Then I bent a piece of 1" aluminum bar to hold the el-cheapo strobe above the lamps. I installed the strobe using its cheap threaded lugs, but decided to not tighten them very much since someone else mentioned that they'll break out of the housing.
Next, I drilled and tapped more 8-32 screws to hold the strobe bracket onto the plate. I didn't have time to find the washers.
Finally, I drilled and tapped 10-24 screw holes for the light brackets. One screw each in the center, so they can rotate. I found the #10 washers with the screws. If any of this stuff vibrates out I'll just locktite it. I can find that faster than the washers...
I bought the lights at the box auto parts store. I know, I got driving lights, but I think the spot will be big enough. If I don't like them, I'll replace them with floods.
Tada! I'll wire it up soon... I already bought the relay and relay holder, so I'll add a bracket next to the fuse panel and use the headlamp wires to close the relay. I'll post another picture when I get that done.
Regards,
Just Gary