Worlds Cheapest Light Bar

Photos

(4) off-road lights (fog-light style, clear glass cover), estimated cost: $40 ($20/pair) (source: AutoZone)
(1) 4ft or 6ft heavy duty signpost: U-type, 1/8" thick, estimated cost: 6ft: $6 (source: Agway, Hackett's True Value, etc--most farm supply or hardware stores)
(2) spools of 14ga. wire (red, black), cut to fit, estimated cost: $8/100ft spool if you don't stock wire (source: AutoZone, Advance Auto, etc)
(1) quick-disconnect harness, estimated cost: free/cheap from a junkyard
(1) piece of spare stock-steel (regular bar-type).. free/cheap from a friend
(6) 5/16" x 18 steel grade 2 bolts, estimated cost: $2.50
(2) 5/16" wingnuts, estimated cost: $1.50

Total Cost: $50.00 if you've got the lengths of wire handy.

Estimated Build Time: 2hrs to measure/build brackets, 1hr to mount lights and bar, 1hr to wire and every night to test.

Piggy-back to hood hinges on a Jeep (measure between outside edges of hinges attached to cowl)
Mounted between overhead roll-bars on a Jeep with the top off.
U-bolted to a roof rack on most SUVs, similarly equipped station wagons (Subaru Legacy, Forester, ...)
U-bolted to a bed-mounted rollbar or frame in a pickup
..get creative, you see my point, its pretty much universal

Start by cutting the bar (signpost) to length. I measured and cut at 33" even, wanting to mount to the outside Torx bolts on my hood-hinges.
Measure length and sketch/visualize shape of your brackets. This will vary and involve more/less time than mine, depending on how you mount it.
Bend/mould brackets as you need to; fit to shape. Mine ended up being a "U" shape, a hole roughly straight down through.
Test fit *everything*.. repeatedly.. before drilling.
Measure/drill bar to fit brackets.
Measure/drill bar to fit lights. (With 33" bar and 4 lights that are 2 3/4" from center to edge, it ends up being 8" of space on the bar for each light)
Attach lights to bar
Attach brackets to bar
Attach brackets to vehicle
Run your wiring harness temporarily for testing. Use a relay to avoid overloading your switch.
Once tested successfully, run your harness permanently, attaching to safe non-movable parts. Make sure all connections are clean, taped, and safe from shorts.
Enjoy.

--Jontow 23:03, 15 February 2006 (EST)