1932 Ford Headlight Bar - Lower The Bar - Tech

Here you can see the dramatic difference between the stock base (right) and the one that has been modified to fit flush to the side of the chassis.

To create the headlight bar chassis mount, 3/4-inch steel bar stock is used to extend and mate the modified mount to the headlight bar. Pictured is the completed mount (left) with the raw stock (right).

For added strength, the chassis mounting bar and extension bar stock will need to be notched. Here you can see a close up of how the final pieces looked prior to welding (top).

Once the bar had been marked with a Sharpie, Cornell used an air-driven cutoff wheel to slowly make the initial cuts.

To complete the notch, Cornell followed with a hacksaw and finalized the process with a hand file to deburr any rough areas prior to a test-fit.

With the test-fit complete, Cornell secured the two pieces together with a Vise-Grip and held them tight in a bench vise to prepare them for welding.

Using a Lincoln Electric Precision TIG Model No. 225, Cornell TIG welded the two sections together to ensure plenty of strength for the upcoming bends the bar would receive. He then ground the welds smooth for a nice finished look.

Using an original Deuce front frame clip as a custom jig, Cornell first secured the mounts to the 'rails, and then heated up the bar stock to prepare it for the first of two bends.

With the vertical and horizontal bends completed...

...this gives you a good idea of the amount of fabrication involved to get the headlight bar mounting bases done.

To secure the headlight bar supports to the chassis, Cornell used 3/8-inch bolts with flat washers to bolt them to the existing mounting points Rolling Bones adds to their frames.

Having both supports secured in place, he checked them one last time with a carpenter's level to be sure they were the same height.

Using the headlight bar, Cornell measured and marked the mounting bases with 1-inch masking tape for the amount to be trimmed from their length. This sets the correct proportions of the light bar in relation to the grille shell.

The headlight bar was removed from the car to complete the welding and grinding. The bar was treated to a Rolling Bones signature patina job and readied for installation.

Cornell fastened the completed headlight bar to the chassis one last time using flat washers and 3/8-inch bolts coated with antiseize compound.

The completed headlight bar is low-slung and awaiting its headlights to keep it all legal.

Cornell mounted a pair of vintage Guide 682-C headlights to add the final bit of flavor to the mix.

Here you can see just how nice the new headlight bar fits to the chassis.