Here’s what I’m thinking of for the light subsystem to avoid the need to add additional holes to those sheet metal trays.
Modification to the left and right upper corner bracket. Lightbar endcap sockets into the arm, wires for the light go out the hole and can be ran down the corner of the frame to power source and or switch. I’m assuming those 6.4MM holes in the corner brackets will be recieving heat set inserts so leaving room for nuts or nut drivers shouldn’t be a concern.
End cap would be something along this line. I’m thinking possibly a different, slightly stiffer design than the existing lightbar to try and span that whole gap without needing a center reinforcement. That will use a bit more plastic, but won’t require adding a hole to the frame. This is the existing long variant of the lightbar endcap which will fit those corner brackets as is.
I know the existing endcap pieces are 20mm x 20mm x 20mm. How far apart are they on that top sheet? I’m guessing a 350-400mm span for a ligthbar in between them?
The existing lightbar fits this style LED strip light. http://www.ebay.com/itm/Waterproof-Super-Bright-5M-SMD-3528-600-White-LED-Flexible-Strip-light-DC12V-/221242479044?pt=US_Car_Lighting&hash=item33831451c4 Since it seemed to be cheaply available in quantity.
Anyways, I’ll keep toying with it. The files uploaded here are hereby officially licensed under the Creative Commons Attribution license, unless that won’t let you guys use them for whatever reason in which case i’ll change it to whatever it needs to be.
taz_mini_corner_bracket_lightmount_LR_2_0_a.dwg (57.7 KB)
taz_mini_corner_bracket_lightmount_LR_2_0_a.stl (235 KB)
taz_mini_corner_bracket_lightmount_LR_2_0_a.stp (93.1 KB)