Carli Suspension
17-26 FORD F250/350 4X4 FABRICATED LIGHT BAR
Template Cutout Selection
17-26 FORD F250/350 4X4 FABRICATED LIGHT BAR
Do Not Include Template Cutout
MCQUEEN
190 South McQueen Road
Suite 109
Gilbert AZ 85233
United States
Built to the same standards as the suspension underneath it, the Carli Front Light Bar integrates serious off-road lighting without compromising the lines of your truck. The main striker tube is a single uninterrupted radius rolled from 0.120″ wall DOM, contoured to the factory bumper and matched to the Baja Designs 40″ ONx6 Arc. Fully boxed and internally gusseted 1/8″ steel horns kill flex at the mount; machined 6061 billet end caps finish the ends. Five tabs accept Baja Designs LP and ONx6 hardware. Bolts to existing bumper locations — zero visible fasteners.
Features:
- 0.120" Wall DOM Main
- Internally Gusseted, Boxed, Fabricated Horns
- Precision Fit Utilizing 4 Bumper Bolts
- Hidden Mounting Hardware = Better Aesthetic & Security
- 6061 Billet End Caps
- Accommodates Several Baja Designs Lighting Configurations
- Lights NOT INCLUDED
- Fitment: 2017-2026 Ford F250/F350
Template Cutout Selection (Optional)
The light bar passes through the factory front bumper bezel — the textured plastic panel that fills the lower bumper around the tow hooks. To make that cut clean, we 3D modeled both the 2020–22 and 2023+ inserts and produced dimensionally matched trim templates. Each template fits both the standard and adaptive cruise control versions of the plastic — no separate part to specify. The template snaps into place on the insert and gives you a precise traced outline to cut. We offer these print files, free of charge, so customers can save the cost if they have access to a 3D printer.
- 2023+ Ford Light Bar Cutout Templates:
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- Designed specifically for 2023–2026 model year trucks, this 3D-printed cut template provides a precise guide when trimming the factory bumper plastics for installation of the Carli Front Light Bar. The template fits directly into the designated cut area to help ensure proper placement and a clean, consistent cut.
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2020-2022 Ford Light Bar Cutout Templates:
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- Designed specifically for 2020–2022 model year trucks, this 3D-printed cut template provides a precise guide when trimming the factory bumper plastics for installation of the Carli Front Light Bar. The template fits directly into the designated cut area to help ensure proper placement and a clean, consistent cut.
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Construction
Built to the same exacting standards as the suspension components underneath your truck, the Carli Front Light Bar is a no-compromise platform integrating serious off-road lighting to keep up with the elevated suspension performance of your Carli-Equipped rig, after dark.
The main striker tube is an uninterrupted radius, rolled from 0.120″ wall DOM. Designed to compliment the curvature of the all the factory bumpers, while seamlessly matching the the Baja Designs 40” ONx6 Arc LED Light Bar. The frame horns are fabricated from 1/8″ cold-rolled American steel; fully boxed and internally gusseted, they eliminate flex at the most critical junction on the assembly, where the bar meets the truck – while the mass of the light bar dampens the majority of rhythmic oscillation/harmonic vibrations transferred through the frame and into the bumper brackets; all while keeping the exterior lines tight and uncluttered. Capping off the bar (no pun intended), the 6061 billet aluminum end caps are machined and finished with a “Bright and Brilliant” aesthetic, adding a premium contrast detail to the ends of the satin-black powder coated light bar.
Lighting Compatibility
The Carli Light Bar was designed from the ground up around the Baja Designs catalog. Five light-mounting tabs are welded directly to the tube at multiple positions, each accommodating standard Baja Designs LP & ONx6 mounting hardware with a secure three-bolt clamp configuration. Each light mounting tab features four holes — the rear three accommodate the LP series mounting footprint, while the forward-most hole positions an ONx6 40″ Arc bar slightly forward for an optimized fit and angle. Our prototype builds are running three distinct configurations, all of which look right at home on the bar: five LP6 Pros across the tube, a mixed setup with two Amber LP6s on the outside and three LP9 Racers on the inside, and a clean single 40″ ONx6 Arc. Whether you’re building a chase truck, heading into the backcountry, or just need serious light output for after-dark work, the platform accommodates it without compromise. Lights not included
Mounting
The bar uses four existing bumper bolt locations. In the 2017 to current trucks, there are 8 front bumper bolts; removing the outside hardware won’t require bumper realignment. The outside factory bolts and nut-plates are removed entirely and replaced with a stud-and-nut-plate assembly that pre-attaches to the light bar — making this a one-person install. Feed the upper studs through the factory holes, secure with a nut, and bolt the lower location into the captured nut in the light bar. That’s the entire process; the bumper never leaves the truck.
All hardware sits behind the bumper – zero visible fasteners from the front making for the cleanest aesthetic on the market.
Bezel Trim Template
On 2020+ trucks, the light bar passes through the factory front bumper bezel — the textured plastic panel that fills the lower bumper around the tow hooks. This panel is the only piece that gets modified, and it’s a cheap replaceable Ford part, so a new set of inserts returns the truck to stock at any point should one decide to carry their Carli kit and light bar to a new truck.
To make that cut clean, we 3D modeled both the 2020–22 and 2023+ inserts and produced dimensionally matched trim templates. Each template fits both the standard and adaptive cruise control versions of the plastic — no separate part to specify. The template snaps into place on the insert and gives you a precise traced outline to cut.
Trim just outside the traced line, test fit the bar, then dress the edge to final. Below, the 2020–22 template is shown highlighted in red for clarity; production templates are black.
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