DIY Foglight Brackets for Badlands

[Jonk]

So here's a very specific fringe case for a simple foglight bracket...

Took part in the Thunderbird TSD Rally this year in BC - about 600 miles of navigating backroads in snow, ice, and mud. I needed some solid supplemental lighting for fog and snow conditions and had a pair of good old reliable Hella 500s sitting around. Compared to car headlights from the 90's the Bronco's headlights are incredible, but having an additional set of yellow spotties made a huge difference when the heavy fog rolled in.

There are lots of good nudgebar options already out there, but I only needed a temporary solution.

The Badlands conveniently has easily accessible tow hook bolts, so I did some quick modelling in Fusion 360, test-printed prototypes, and then had a pair cut and bent by SendCutSend for about $80 (awesome service, by the way). I went with 5mm chromoly and these things are rock solid. They bolt on and off in just a few minutes.

I know it’s a pretty niche application, but if anyone’s interested in the files I’m happy to share.

 

[Bach]

These are great! I would love to have some fabbed up.

 

[jkernitzki]

SCS is awesome. A few channels I watch (in particular, Superfast Matt) use them extensively, and the work they do is absolutely first-rate.

 

[Jonk]

SCS is awesome. A few channels I watch (in particular, Superfast Matt) use them extensively, and the work they do is absolutely first-rate.

Haha Superfast Matt is where I learnt about SendCutSend. I uploaded the files, got an immediate quote and had them in my hands in Canada 3 days later. Amazing.

They even had an option for powder coating for $10/pc.

What's really cool is you can import their material profiles into Fusion 360 so when you model the bends you can get the correct radius for whatever steel/aluminum you're using.

 

[Jonk]

These are great! I would love to have some fabbed up.

https://drive.google.com/drive/folders/1rxJ_UzERKjZZmcYPTWnJQrcRP2otzFDc?usp=sharing

Here are the two .STEP files (one for each side) that can be dropped into SendCutSend and a Fusion360 file if you want to tweak anything.

(There are a bunch of discount codes floating around out there for the service.)

 

[Bach]

Thank you so much for sharing. You are the best!

 

[Bach]

https://drive.google.com/drive/folders/1rxJ_UzERKjZZmcYPTWnJQrcRP2otzFDc?usp=sharing

Here are the two .STEP files (one for each side) that can be dropped into SendCutSend and a Fusion360 file if you want to tweak anything.

(There are a bunch of discount codes floating around out there for the service.)

What material and thickness did you use?

 

[Jonk]

What material and thickness did you use?

4160 Chromoly .190” - possibly overkill but those lights did no budge an inch.

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