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yep i have, sorry took a while had to dig it out the shed.
 

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and a side view
 

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that was made with a simple aerosol lid and black electrical tape lol
 
what about the heat... was playing last night got HOT HOT HOT!!
 
yea they do get a tad warm, that light was only run on 12 aa batteries though not a whopping big 12v car battery lol, never melted the plastic tho and they ran for a good hour before starting to lose power, i suppose they keep cool when your moving, so when on a car you can move faster than a mountain bike so should keep them very cool, failing that use alluminium as housing, you can get cheap alluminium torches, I bet the housing off one of them would do, also then you have the extra glass to cover the front already made and in place. I'm thinking of starting a project like this myself, we will have to compare notes on what we find best to use.
 
like the torch idea..

i was also thinking of mounting into so box section. with holes for the lights... will have abash at a draweing later... see what you think
 
i was thinking of something along those lines.
 
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the white down pipe was what i was thinking. cut over the roof rails and "U" bolted on.
 
Most of these lamps are designed to pass most of the heat to the rear, so allow a little ventilation at the back, a couple of small holes at the bottom and a few at the back, will help I would have thought.
Even hack saw cuts may do it, but arrange them so direct water doesn't gets in and onto the rear of the lens or on to your connectors.

You will get some light leakage, so you could always include a small matt black baffle behind the lens.

What you really need is some matt black anodised aluminium tube. Or even stainless, there are several suppliers of standard Aluminium tube on ebay.

You have me thinking about this one..... They should fit nicely behind the grille as well.
 
i did thing of 90 deg elbows to alow air up and in.. out at the ends.
 
I wonder if resin would make a good housing? could mould vent holes into it that face down without any bother, not sure if it would cope with the heat though.
 
Ive seen something like that before :lol
 
another step closer..


ive got myself a 1M of this .. will use to fit lights on.

any one else use it befor??
 

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here we go...
what im going to fit lights too...
can get a bit more if any one else would like some....
251010-1720003.jpg
 
I really cant see why you're bothering!!

Well actually I think I can..

I am tight as a gnat's chuff when it comes to spending money!!! The train of thought is going well, using what you can find!! So long as you get the stuff for nowt. I wouldn't want to be buying tube and paying PnP or lengths of cable tray. Good Idea!

If your going to use the cable tray make sure it is heavy duty which is punched - bent then galvanised, not light duty that is punched out of pre galvanised sheet then bent, this will rot faster than a 3 week old cabbage.

If I were going to span the roof bars I would use 41x20mm Slotted Unistrut ( readily available ) which you could also use as roof bars it is sooo much stronger and you can under sling the lights!

WRT Dichroic halogen bulbs, aswell as cracking if you get water on them, they do not like vibrations too much either!! The ones we have in our bedroom in the loft conversion have probably been there for over 10 years and we've only changed the odd one!
The ones in the kitchen, which is below the bathroom, need replacing regularly due to the sampeeding hoards of kids upstairs!!!
 
Watch the overall height, multistory car parks, and the barriers at waste sites could be an issue.
You could mount the strip under the roof bars, (turn it over so flat at top)may be more streamlined
 
did you ever get this project finished?
 
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