Defender tube bar design....opinions

Beautiful work from you as usual Murray.
I think that the holes in the gussets make it look a bit "busy", so I prefer the second version.
Pickles.

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Originally Posted by dullbird

is this made so you can weld in different plate fitments depending on which winch you have?

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I've done a version with the standard mounting hole pattern for most electric winches, also a version to fit the Thomas PTO. As you can see, the middle section of blue RHS is in between two flat plates at either end. If someone wanted to customise a bar to suit something different or unusual, then I'd probably be willing to supply the bar with the centre section left out.

Cheers, Murray

The holes in the RHS are the standard 10" x 4.5" (254mm x 114mm) electric winch layout.
https://www.aulro.com/afvb/images/im...14/04/1245.jpg

Voting done, awesome work Murray!

....on second thoughts, damn you Murray, I'm gonna end up spending a lot of money on your gear at the back end and now front end of me new Deefer (when it finally shows up!)

Hi Murray,

Do you know if the new bar will fit SVX/X-Tech Special Edition grill head light assemblies.

Your pics look like it is very nicely tucked around the the head light surrounds, maybe too tucked for SVX/X-Tech.

Very nice work though, as per normal.

Cheers
Grant

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Originally Posted by Drover

Hi Murray,

Do you know if the new bar will fit SVX/X-Tech Special Edition grill head light assemblies.

Your pics look like it is very nicely tucked around the the head light surrounds, maybe too tucked for SVX/X-Tech.

Very nice work though, as per normal.

Cheers
Grant

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The main tube sits just below the headlight panel, so no problem. It was the little bracing tube that had to be modified on the other brand bar because in standard form it occupied the same space as the plastic indicator surround on the SVX type front.
Whether I fit a gusset or a tube it will clear.

Cheers, Murray

https://www.aulro.com/afvb/images/im...14/04/1230.jpg

Voted........oh and sent a pm or two

DB's idea is a nice touch......

I just had a look at the poll results. Surprisingly it's a 50-50 even split. I expected it to be heavily bias towards one design or the other.

Cheers, Murray

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Originally Posted by clive22

Hi Murray

I like the idea of the gussets,but can't help thinking that a twin gusset for strength appropriate on this key connection, with the plates mounted one on the front and one on the back of the main bar - sandwiching the two tubes.

That way when the bar is impacted the front plates are in tension and rear in compression - this decoupling in widely spaced plates adds a lot the strength over a single.

These gussets would help in increasing the strength of the loop to main bar welds especially under fast acting dynamic loads impose which tend to lead to brittle fractures.

The tops of the gussets should be capped (another section of steel) for the most part along their length to a impacts on the upper tube can be transmitted at least to a limited extent in torsion to the main tube and take the load off the cantilever tube.

For myself I would leave out the material saving holes strength is critical with multiple force systems though this section.Except keep you've got three the 'mouse hole" in the corner - this raises weld stresses.

That's just my opinion and because I think bull bars should be for strength - keeping 'roos out of the radiator before anything else.

Will this fit a Tomas PTO winch if so I'd be interested.

This will add to the cost but why not make it a good as can be there's plenty of nearly the sames out there

Clive

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Second that!

I love the gussets and I reckon by going with some double gussets you'd be way ahead of the bell curve. Also in my humble opinion I think you could use a single piece to act as the floor for the winch, the top of the chassis mounts and connect it up to the main tube if that makes sense.

I only say that as in some shots it seems like the main tube hasn't got much purchase on the cradle.

Other than that looks awesome and I'd prefer to buy one from you that's distinct and stronger than just an improved version of the rovacraft one. Keep is posted on price an availability!

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Originally Posted by Wicks89

Second that!

I love the gussets and I reckon by going with some double gussets you'd be way ahead of the bell curve.

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I'm thinking of combining a couple of suggested ideas. I agree, the double gusset would be stronger, and Dullbird suggested fitting DRLs into the gusset, so by boxing in the top of a double gusset it would provide a cavity to neatly hide the wiring away.
This is just a quick Photoshop pic, but it would look something like this.
https://www.aulro.com/afvb/images/im...14/04/1192.jpg

Also, for the bar I'm building for my own car, I've housed some DRLs into the main tubes. I'm hesitant to offer this as an option because it's a lot of work to box the housings, but if someone really wanted them, it can be done. It would add at least $200 to the cost including the lights, mainly because of the time involved.
https://www.aulro.com/afvb/images/im...14/04/1193.jpg

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Also in my humble opinion I think you could use a single piece to act as the floor for the winch, the top of the chassis mounts and connect it up to the main tube if that makes sense.

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That makes perfect sense, and I did consider that sort of design to simplify things a little. The reason for the current design is so the middle section is easier to adapt to different winches, or even to a lighter non-winch bar.

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I only say that as in some shots it seems like the main tube hasn't got much purchase on the cradle.

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Keep in mind, the bar in the pics is only tacked together. I will be adding additional bracing, for example, between the main tubes and the chassis mounts.
https://www.aulro.com/afvb/images/im...14/04/1194.jpg

Thanks for your input.

Cheers, Murray

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Originally Posted by DieselDan

Voting done, awesome work Murray!

....on second thoughts, damn you Murray, I'm gonna end up spending a lot of money on your gear at the back end and now front end of me new Deefer (when it finally shows up!)

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:D Might have to put a special package deal together for you Dan............

• Dual rear carrier
• Front winch bar
• Telescopic light pole
• S/S wingtop vents
• Oh, and I'll throw in a cup holder or two for free :D

And any new products I come up with in the future, I'll just send them to you with an invoice :D:D............you know once you get a Defender, adding or changing things is never ending.

Cheers, Murray