Creating the Nerf Bars

• The lighted nerf bar is made in the same way as any other nerf bar: a 3-inch steel tube of either aluminum or a high-grade steel is sized to fit your particular truck. The pipe is set into a metal bender; the area behind the bend is heated using a blowtorch or heat gun. Then the steel is bent to shape. Normally, a simple 90 degree curve is placed in the nerf bar. The step is then covered with a rubber step guard, available from auto parts stores. This is applied to the nerf bar surface using steel bolts. Holes are drilled through the step guard and into the nerf bar, and it is bolted in place.
  
  

Adding LED Lights

• Add LED light bars to the nerf bar along the side. There are many ways to accomplish this task. The easiest involves attaching the light bar with small metal screws right along the side of the bar.
  
  First mark holes in the side of the bar with a marker through the mounting holes on the light bar. Then drill a second hole for the wiring to the light bar. Use a 1/4-inch bit for this hole. Then drill a pilot hole for the mounting screws, using a small carbide drill bit, one that is half the size of the attaching screw. Finally, install the light bar with a power driver.
  
  

Wiring Tips

• The wiring to your light bars is a complicated task that involves knowledge of electrical systems. Check your wiring diagram to locate an open fuse slot for the light bars. Fuse boxes are located in the console, under the glove box and in the truck dashboard on most trucks. Add a wire directly from your console or dashboard fuse box to the nerf bar.
  
  The most effective method is to run the wire under the carpet and through the bottom of the truck floor to the nerf bar. Feed the wire through the end of the nerf bar to the light bar. It helps if you remove the nerf bar and thread the wire through the end, then reattach it. Inspect your truck chassis for additional wiring routes that make more sense for your vehicle. It is important to protect the wire if you run it along the outside of the nerf bar or truck at any point. Rubber sheathing or a conduit is the best option.