Is it possible to build a Pro6 bar out of spare parts available on KCHiLiTES.com? – KC HiLiTES

Short answer: YES! (mostly)

It is now possible to order almost all of the parts needed to build your own Pro6 bar with parts available from KC HiLiTES dot com.

We will build a 7-light or 45” Light bar for this article.

Here is a list of parts you’ll need to purchase from KCHilites.com to have everything you need to build your own Pro6 bar:

End Mounts (1 each Side-specific).

This mounts the bar to the bracket that will hold the bar in place.

Front and Back rings + (some) Hardware.

These hold the LED inserts, link together, and also connect the end mounts. You’ll need 1 each for each light you plan to have.

You will still need to Source your own nuts and bolts to fit the front ring to the back ring. So far this is the only part we do not (yet) sell on our website. You can find these in most hardware stores.

KC HiLiTES uses four M6-1x16 bolt/nuts to hold the front and back rings together. We're working on getting a set of these for sale on the KC HiLiTEs Website to make things easier. For now, they can be found at any hardware store that sells bolts/nuts.

LED Insert

We call the light itself an LED Insert. This is the assembly with the housing, lens, reflector, LEDs, internal electronics, connector and plug that gets sandwiched between the front and back rings.

We use a combination of Wide-40 Inserts on the outermost location while using the Spot beam in the center section. You can customize your Pro6 bar with a setup that works for your specific needs.

Wiring

We recently updated the design of how our harness works. We now have a two-piece system to clean up wiring installs from your lightbar to your engine bay. The first part is the switch harness that connects to your battery. It includes the fuse, relay, and switch assemblies. This then connects to the second part that then branches off to connect each individual light.

This is enough to get the Bar put together, plugged in and working.

However, it’s important to have Light Covers, and we highly recommend Light Shields to protect the lens and improve visibility in harsh conditions.

How we define covers and shields:

Covers = no light can pass through

Shield = allows light to pass through

On public roads, blackout covers are required by most law enforcement authorities around the world to prevent blinding oncoming drivers or causing distractions.

For off-roading, we highly recommend using a light shield. Light shields allow light through while protecting the lens from damage. Branches, bushes, sand, and rocks could damage the light, and the light shield provides a level of protection. It's easier and less expensive to replace a light shield than an LED Insert. We carry Light Shields in Clear or Amber.

Light Locks

One last accessory we highly recommend is a set of KC Light Locks. Protect your investment!

KC LKZ - M8-1.25 Light Lock Security Nut Set

And that is pretty much every part you need to have a full Pro6 Light bar.

But what if you want to move your 7-Light Pro6 bar off of your Side by Side and put it on your full-sized vehicle instead? You can use the existing parts list to build your own add-on kit, but we’ve made it easy and put everything together to add a light to an existing Pro6 bar.

Pro6 Gravity® LED - Add-On Driving Light System - 20W Spot Beam

-(1) KC Gravity® LED Pro6 Driving Beam Light

-(1) Light Cover - Black w/ Yellow KC Logo

-Complete Hardware Set for Install

-DT Connector with pigtail to tap into existing harness

Adressing Gen 1 Pro6 compared to Gen 2 Pro6

KC HiLiTES has released two versions of Pro6 hardware (Back Rings, Front Rings, and End Mounts). The 1st Generation Hardware had some fundamental structural issues that would cause the bar to break in extreme driving conditions. We researched the issue, received feedback, and significantly improved the structural integrity of the Pro6 hardware with the 2nd Generation Pro6 Hardware. We now have zero cases of the 2nd Generation Pro6 Hardware breaking in extreme conditions. This excludes accidental damage like rollovers or other types of direct impact beyond the intended design of the bar.

Please note that 1st Generation and 2nd Generation Hardware do not connect and do not fit with each other. If you have a damaged Gen 1 bar, you will need to replace all the hardware with Gen 2 parts. Reach out to our Customer Experience team for support and to check if your case qualifies for a no-charge Warranty.

How to Contact KC

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