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I know i'm rehashing old stuff here but someone asked for the info,
When i was looking for a light bar i could'nt see anything on the market that i liked, most of the "bought" ones looked like half a roof rack,
I made mine out of two 1mt lenghts of 20mm alloy box from B&Q and some 3-4mm flat alloy plate, First i made a card template for the side supports, when it looked right i transferred it to the plate and cut to shape, the most fiddley bit was getting the angles right for the contour of the roof, i positioned these a little more inboard from the edge of the roof than i wanted so as to miss the double skinning inside the roof, i used "bigheads" with double sided tape (to stop em turning) and 3/4" tap washers under the support feet to stop the water getting in (along with a little black silicon sealant) once these were in place i cut the box's to lenght and made up some alloy "plugs" to press into the onen ends and fixed them in place with alloy covered head pop rivets, then i drilled and tapped each end of both bars to take some threaded rod and s/s dome nuts, use locktight on all threads to stop em viabrating loose,
Thats the main bars!! next i made the light holding plates, (X4) this is approx 30mm X 3mm flat alloy plate, bent and drilled and fixed across the two bars with threaded rod and s/s dome nuts, (used this throughout so it all looks the same and wont rust like regular bolts) at this stage i decieded to fit 7 amber 10mm leds along the front edge, i ran all the wireing through the forward bar and into the rear one via some "fluted tubeing" from VWP, also used this along with some terminal weatherproof ends to take the wireing through the roof, i wanted s/s bradeing but could'nt get it, this looks OK though,
Thats about it as far as the bars go except to say i gave all the alloy bits a good going over with autosol on an electric mouse pad, it dose'nt need laquer as it's kept it's shine and only need a quick rubover with autosol when it dull's,
I appoligise for the pic's of em on as i only put em on in the garage for the pic's, to see what they looked like, had to take em off again to get the truck out, now i got the clearance i aint got the time to fit em properly,
The light's i used by the way are 3 1/2" blue glass spots (to match the six on the front) i also used two with amber glass on the front as foggies, Finally regarding the light fixing's i did'nt like the look of the threaded bit and steel nut, luckily i had some s/steel dome nut's the same thread, so i cut the thread to the right lenght and used them, i think it finishes em of a bit, and they wont be rusty the first time it rain's,
Think some of these pics are in cinema scope (photobucket) Sorry
I'll take some better pics when i get em on properly, you wont see all that wireing then,
When i was looking for a light bar i could'nt see anything on the market that i liked, most of the "bought" ones looked like half a roof rack,
I made mine out of two 1mt lenghts of 20mm alloy box from B&Q and some 3-4mm flat alloy plate, First i made a card template for the side supports, when it looked right i transferred it to the plate and cut to shape, the most fiddley bit was getting the angles right for the contour of the roof, i positioned these a little more inboard from the edge of the roof than i wanted so as to miss the double skinning inside the roof, i used "bigheads" with double sided tape (to stop em turning) and 3/4" tap washers under the support feet to stop the water getting in (along with a little black silicon sealant) once these were in place i cut the box's to lenght and made up some alloy "plugs" to press into the onen ends and fixed them in place with alloy covered head pop rivets, then i drilled and tapped each end of both bars to take some threaded rod and s/s dome nuts, use locktight on all threads to stop em viabrating loose,
Thats the main bars!! next i made the light holding plates, (X4) this is approx 30mm X 3mm flat alloy plate, bent and drilled and fixed across the two bars with threaded rod and s/s dome nuts, (used this throughout so it all looks the same and wont rust like regular bolts) at this stage i decieded to fit 7 amber 10mm leds along the front edge, i ran all the wireing through the forward bar and into the rear one via some "fluted tubeing" from VWP, also used this along with some terminal weatherproof ends to take the wireing through the roof, i wanted s/s bradeing but could'nt get it, this looks OK though,
Thats about it as far as the bars go except to say i gave all the alloy bits a good going over with autosol on an electric mouse pad, it dose'nt need laquer as it's kept it's shine and only need a quick rubover with autosol when it dull's,
I appoligise for the pic's of em on as i only put em on in the garage for the pic's, to see what they looked like, had to take em off again to get the truck out, now i got the clearance i aint got the time to fit em properly,
The light's i used by the way are 3 1/2" blue glass spots (to match the six on the front) i also used two with amber glass on the front as foggies, Finally regarding the light fixing's i did'nt like the look of the threaded bit and steel nut, luckily i had some s/steel dome nut's the same thread, so i cut the thread to the right lenght and used them, i think it finishes em of a bit, and they wont be rusty the first time it rain's,
Think some of these pics are in cinema scope (photobucket) Sorry
I'll take some better pics when i get em on properly, you wont see all that wireing then,
I'll definitely buy a pair of those.
maybe if its nice this weekend ill do it (should that be weather or wife permitting!!? keep up the excellent mods mate 
If I do manage to draw a blank in making
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