Thread: Defender tube bar design....opinions

I think the braces look silly and you might aswell get rid of them, strenght can be added in other areas.

Why do you not continue the main tubes to completely overlap the chassis boxes/mounts?

Cheers
Will

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

Originally Posted by MR LR

...........Why do you not continue the main tubes to completely overlap the chassis boxes/mounts?

Cheers
Will

The main tubes stop where they are because if they went further in they would be in the same space as a winch.


To run them in further they would have to come forward which would decrease the approach angle at the wheels.
I've got the main tubes tucked in close to the body, but not too close.
Also, the ends have a radius to follow the line of the body.

Cheers, Murray

[IMG][/IMG]

Originally Posted by clive22

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

Clive

Yes, I've already done a PTO version on request of another forum member. As soon as I finalise a few details it will be off to get hot dip galvanised.

Cheers, Murray

Nice design there Murray, the only criticism I have is that the winch tray does not pick up the plates on both sides of the chassis rails (unless you're planning on adding material?), you could do this without any ill effect on approach angle, however as I've mentioned before I like to over-build things.

Otherwise it looks awesome, the curved corners give it a very 'finished' look.

Regarding the bracing, I think a straight tube going up to the A-bar, (so get rid of the bend) mirroring the one beneath would look the best and give the best trade off between strength and looks.

Cheers
Will

Voted. Overall, I like it!

Got my vote, wish you had finished this before I bought my rover craft.

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