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Off road lights on bull bar

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I just received my KC off road lights and after an initial overview, it looks like the lights are too tall for my bull bar unless I remove the "cup" just below the light and above the rubber washers. If I remove the cup I am afraid they won't stay in position after I adjust them though. Plus the rubber washers are flat and my bull bar is round. Has anyone rigged something like this before? Unfortunately my bull bar isn't big enough to accommodate the full mounting system. I figured the lights would come with some hardware for mounting to a bar but it looks like these are designed for mounting to flat surfaces.

I have a Steelcraft bull bar and KC HiLites 233 Daylighter 6-inch off road lights.

Also how are you supposed to get the washer for the inside of the bar inside the bar? It is about 3 times larger than the hole on the bottom of the bull bar. I was thinking about pushing it all the way up and through the bull bar with a coat hanger. I really don't want to return the lights since that would be a PITA but if there is no way to make them work I suppose I will have to.

First shot shows the full mounting system, second shows what I have to do for it to not be too tall to fit between the bars.

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Discussion Starter · #3 ·
Ok it sounds like I have both problems then. I didnt realize the bolt was supposed to go entirely through the 3" bar. So the bolt isnt long enough and the lighrs are too big. Sounds like a return to me.
 

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Discussion Starter · #5 ·
Yeah the interior of my bull bar isnt accessible. After some more thinking I am going to try relocating the light mount a couple inches forward so i can clear the upper bar with the lights. Should I just go to a hardware store to look for something that might work for the relocation bracket?
 

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Discussion Starter · #9 ·
Alright I got the lights mounted and wired and when I turn them on, one of them doesn't work. One does, one doesn't. I tried to find a troubleshooting guide online but no luck. I grounded both lights the same, on the mounting bolt. I don't know what would cause one to not work other than a bad ground.
 

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Discussion Starter · #11 ·
It was a bad ground. The grounds are VERY touchy in this kit. This is pretty much the first electrical work I have ever done, so maybe all grounds are that touchy but I had to try a few different positions before the ground worked. Hopefully it continues to work. :158:
 

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Discussion Starter · #12 ·
Here are some pics of the mounting system I came up with. I found some scrap metal laying around that I cut into two brackets to mount the lights a couple inches forward. They are pretty solid. I don't think I will have issues with anything moving. I still need to paint the brackets black but I wanted to mount things up today to make sure it would work. I angled them slightly out to put the lights a little farther from each other.
 

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Discussion Starter · #14 ·
Yeah I was really happy to find that metal laying around. My dad practically has a junkyard at his house so I found multiple pieces that would have worked but this particular piece already had holes drilled in it that were the perfect size and distance apart. I just had to cut the metal. It even has a lip on each side which should make it stronger.
 
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