DISCOVERY 2 STEEL REAR BARS!!

[Hendrik]

Hi All

Most D2 owners know how fragile the standard plastic rear bar is, so finally a tough, affordable steel replacement that doesn't outweigh the car.

I've spent a lot of time developing my new steel rear bar, which is now ready.

About this bar:

IMPROVED DEPARTURE ANGLE:
An increase in departure angle from 21 degrees to 26 degrees, on a standard vehicle with standard suspension and tyres.

LIGHTWEIGHT BUT TOUGH:
Weighs approximately 16kg, which is only 4kg heavier than the original plastic bar.

STRONG MOUNTING:
Mounts to the chassis with 6 bolts at 3 points

OPTIONS INCLUDE:
Lights: LED or stock lights can be retained
Two rear recovery points
Wheel carrier: still in development, but should be available soon (will add pics)

https://www.aulro.com/afvb/images/imported/2011/02/1345.jpg

https://www.aulro.com/afvb/images/imported/2011/02/1346.jpg

https://www.aulro.com/afvb/images/imported/2011/02/1347.jpg


PRICE:
Standard Bar (as seen in pics) $550

Will update this thread soon with some better photos and prices for the options.

CONTACT:
Email: hrik13@hotmail.com
Mobile: 0448181223

[Tombie]

Looks nice mate... Sleek and smooth...

Best of luck...

[Hendrik]

Thanks Tombie, hope everyone else thinks so too

[dobbo]

Thanks Tombie, hope everyone else thinks so too

Looks good.

[Narangga]

Looks nice mate... Sleek and smooth...




Looks good.

Yep sure does.

Await the wheel carrier version with baited breath. Will it be a single or dual carrier?

[grover7488]

looks great. Factory look. will they be powder coated?

well done :cool:

[Hendrik]

Thanks.

It will just a single wheel carrier for now, can develop a dual wheel carrier as well, but it depends on how much interest I get.

At the moment I am painting the bars with two pack, but I can get them powder coated as well.

[Sully]

Well done mate. Looks the goods!

[clubagreenie]

I'd be keen on a dual mount.

Two tyres or tyre and jerry or 2 tyres & 2 jerrys or ...

Possibly make compatible with off the shelf available mounts. Would need someone to offer up samples though.

[stuee]

Looks the goods and great price!! So when's the D1 model being made :angel:

[Hendrik]

Yeah I am using off the shelf stuff, will try to have some pics of the wheel carrier by the end of next week.

I have a D1 bar in the pipeline, just need someone willing to lend me their car for a day.

[clubagreenie]

just need someone willing to lend me their car for a day.


Can you make it to sydney?

[IceFyre]

If you do a 'Deluxe' bar, with say dual carriers (Single would even be ok) and the bar extends along the quarter panel I will 100% take one. Do you do custom requests ? :-) My rear bar has been missing since Cape York in 2009 awaiting a good replacement.

[Hendrik]

Can you make it to sydney?

I can but my workshop can't haha.

I can do custom requests for all the gear I sell including the sliders, quarter panel protection on the rear bar is also something I am currently looking into.

[dullbird]

Why does no one ever make them for a D1 :(

[Hendrik]

If I get enough interest, I will get the ball rolling on a D1 rear bar. I have a rough design in mind, will try to make it look like the stock bar.

I have a mate with a D1, might see if he is keen for me to use his car to start a design.

[dullbird]

If you make a good D1 bar that looks just like the stock one I would be really interested that's for sure:)

[stikman]

If I get enough interest, I will get the ball rolling on a D1 rear bar. I have a rough design in mind, will try to make it look like the stock bar.

I have a mate with a D1, might see if he is keen for me to use his car to start a design.

If you are keen to make an offroad D1 rear bar, including rear qtr protection and to suit a body lift my D1 is sitting there waiting :D shoot me a PM or give me a call 0414744744.

[bolts]

Would be very interested in one for the D1 as well... Looks like you have a few people with D1 to start work on ;)

[rangieman]

I could be tempted in a D1 rear bar if the price is right;)

[ptaplin]

Count me in for the D1 if it looks good!

[Hendrik]

Guess I better hop to work then :D

[twr7cx]

I assume asking if their are fittings for the rear parking sensors is dreaming?

[Hendrik]

Not at all, its just a matter of drilling the holes for them. I will look into the way that they are attached.

[twr7cx]

Not at all, its just a matter of drilling the holes for them. I will look into the way that they are attached.

They're a round hole, with a locating slot at the top (only about a 1mm), the holders push in from the outside of the bar, and the sensor itself pushes in from the back inside the bar into the holder and then a 20* turn to lock the lug in.

[Basil135]

The sensor takes a 27mm hole, plus the locating lug....


Go on, ask me how I know..:D






BTW - drilling a hole that size in 5mm steel is not something that I want to try again. Next time, the first stop will be at the engineering shop.:eek:

[rangieman]

Guess I better hop to work then :D
Any update on the D1 rear bars:cool:

[Tombie]

For a D1 thats lost its corners it would be easy for anyone to make a template and just fabricate some corners up to make it look neat...

Just a thought...

If you're after the whole box and dice then thats different ;)

[GEK064]

looking real good..... do these come painted/powder coated?

[vogue]

Great stuff, would love to see one with duel jerry can holders on it;)

[twr7cx]

Does it fit the D2a refresh model aswell?
What do the LED light option look like?
I think my D2a has the indicators up high and the reverse lights and rear fog lights down the bottom in the bar.

[Hendrik]

looking real good..... do these come painted/powder coated?

They come painted as standard, with powdercoating as an option. I am yet to get one powdercoated, but can find out a price.

[chuck]

Hendrik

Do you have any rear bars in stock.

What would be the price powdercoated & delivered to Melbourne?

Do they fit a D2a?

Regards

Chuck

[twr7cx]

They come painted as standard, with powdercoating as an option. I am yet to get one powdercoated, but can find out a price.

What's the difference between painted and powerdercoated? Is powdercoated just a more durable paint job?

[twr7cx]

Does it fit the D2a refresh model aswell?
What do the LED light option look like?
I think my D2a has the indicators up high and the reverse lights and rear fog lights down the bottom in the bar.

?

Also got a picture of the rear recovery points?

Happy to organise freight?

I'm keen, just wanting more information before I lay down the dollars...

[Hendrik]

I don't have any in stock at the moment but I am planning to make a few bars next week. They do fit a D2a.

PM or email me if you are interested.

[Franz]

The sensor takes a 27mm hole, plus the locating lug....


Go on, ask me how I know..:D






BTW - drilling a hole that size in 5mm steel is not something that I want to try again. Next time, the first stop will be at the engineering shop.:eek:
I did this using a commonly available hole saw - wasn't too difficult.

Cheers,

Franz

[peter5111]

I did this using a commonly available hole saw - wasn't too difficult.


+1

The blue Sutton bi-metal hole saws are lovely for this sort of thing. I don't have a 27mm but I do have the arbor. If anybody in the Adelaide northern suburbs needs to do a couple of holes it would be a neat excuse for me to pick up a 27mm for the collection.

Pete

[Hendrik]

Well I've finally got around to posting some painted and fitted pics of this bar.

https://www.aulro.com/afvb/images/imported/2013/03/481.jpg

https://www.aulro.com/afvb/images/imported/2011/07/1420.jpg

https://www.aulro.com/afvb/images/imported/2011/07/1421.jpg

https://www.aulro.com/afvb/images/imported/2011/07/1422.jpg

[Player1]

My discovery got touched up by a bus, left rear panel has a major crease and a couple of puncture holes, tail light has a broken corner and rear bumper has a small tear. Anyway insurance will cover the repair so I'm keen on replacing the plastic bumper with your new beaut steel version, I need to know what options you can provide on top of your basic design. I'm interested in the powder coated version with recovery points and do you provide the holes for the sensors? It seems sensible to have the holes powder coated as well instead of drilling them later.
Price and availability would be appreciated.

Cheers:beer:

[rijidij]

Hendrik, would your bar be strong enough to support twin wheel carriers with stub axles inserted through and welded into the bar itself.
I've had a couple of requests for wheel carriers for D2's (dual & single) with the standard bumper, but I haven't had the time to design anything. A replacement bar is a much better option. I make all the carrier components so it probably wouldn't take too long to sort something out to integrate into your bar.
It's just a thought at this stage anyway.

Just one question.......what is the distance from the back of the bar to the top trim, ie how much flat surface is there to play with (see pic below)
My hubs are 70mm dia.

Cheers, Murray

https://www.aulro.com/afvb/images/imported/2011/07/1121.jpg https://www.aulro.com/afvb/images/imported/2011/07/1122.jpg

[Tombie]

You mean something like this:-

http://gallery.me.com/rovertech/100287/Image0060/web.jpg'ver=12751159360001
http://gallery.me.com/rovertech/100287/IMG_4886/web.jpg'ver=12751159370001

[rijidij]

You mean something like this:-

Yeah, like that. Have you got the carriers to go on there, I can't see any latch plates etc, or is it an unfinished project........we've all got them. :D

Cheers, Murray

[Hendrik]

Hi Murray

The clearance you indicate would be ideal, however the problem is the tail light inside the bar, I guess I could let the bar sit out a bit more and then there should be enough clearance to fit the hub inside the bar.

The bar should be strong enough to hold two wheels, if not I can always go to a 4mm wall. I have limited experience with wheel carriers, but I was going to try to simplify it a little. My question to you is whether it is really necessary to have a hub and bearing set up. Wouldn't a hub with a nylon bush be able to take the weight of the wheel and still provide sufficient smooth movement of the carrier?

I will keep your kits in mind, as they are very well designed and you have a good reputation and who knows I can always get wheel carrier kits from you and adapt them on my bar....it will save me a lot in labour time.

[Tombie]

Yeah, like that. Have you got the carriers to go on there, I can't see any latch plates etc, or is it an unfinished project........we've all got them. :D

Cheers, Murray

Murray

When building the bar I put them in but havent had need at this stage to build carriers.. Just there "in case"...

PM me though, I think I'll build some using your gear :cool:

[rijidij]

Hi Murray

The clearance you indicate would be ideal, however the problem is the tail light inside the bar, I guess I could let the bar sit out a bit more and then there should be enough clearance to fit the hub inside the bar.

Hendrik,
The stub axle that would go through the bar is only 40mm and the hub which would sit above the bar is 70mm. The tail light could possibly still be a problem, but with dual carriers you need the stubs pretty close to the ends, so hopefully it would work.


...............My question to you is whether it is really necessary to have a hub and bearing set up. Wouldn't a hub with a nylon bush be able to take the weight of the wheel and still provide sufficient smooth movement of the carrier?

Yes, a nylon bush would be fine as far as load bearing and smooth operation, but would be more vulnerable to dust etc and would eventually wear. The tapered bearing type setup is sealed from dust and torqued up allowing zero movement. With very minimum maintenance over the years, you should never wear the bearings out.

Cheers, Murray

[mrsshimmy]

Hello,
We own a '02 Series 2 Disco & I made a rear bar for it in my shed. I made it because I couldn't find a nice looking bar or anyone to make me one for a reasonable price. I kept the same shape as the original bar, I cut out the rear quarter panels by about 7 inches & welded side protectors onto the bar. I can actually jack the car up from this.
I put a jerry can holder on it with a swing arm plus other features. If you want to have a gander look it up on youtube - just type in LIFTY1234 which is my channel & there's 2 videos of me making it & completing it.
If anyone has any questions, I am happy to answer them.
I found the other info on this post interesting to read. Cheers.:D

[disco_ute]

Hello,
We own a '02 Series 2 Disco & I made a rear bar for it in my shed. I made it because I couldn't find a nice looking bar or anyone to make me one for a reasonable price. I kept the same shape as the original bar, I cut out the rear quarter panels by about 7 inches & welded side protectors onto the bar. I can actually jack the car up from this.
I put a jerry can holder on it with a swing arm plus other features. If you want to have a gander look it up on youtube - just type in LIFTY1234 which is my channel & there's 2 videos of me making it & completing it.
If anyone has any questions, I am happy to answer them.
I found the other info on this post interesting to read. Cheers.:D

PIC?

I need to make one for the wife's car looking for ideas

[FireFox]

im deffinatel;y interested in a D1 rear bar.

[greg smith]

Need a new rear bar for my d2, do you have one ready,with standard light fittings? How much$??
thanks
Greg Smith

[boofdtl]

im deffinatel;y interested in a D1 rear bar.

+1 for the D1 bar

[Rosmac]

HI CHAPS
I am looking for a rear bar for my disco 2 with jerry holders. Any clues on where and what.
Regards
Ross

[dullbird]

did you ever get a bar made for the D1 hendrik? seems you have more interest in this trhead for D1's than D2's

[gavinwibrow]

PM sent

[SimonM]

did you ever get a bar made for the D1 hendrik? seems you have more interest in this trhead for D1's than D2's

Yep another interested in the D1 bar, or should i say my wife is as it is her car ;).

[transtar]

Any further news on rear bars with spare and /or jerry carriers to suit Disco 2

[gavinwibrow]

Hi Murray

The clearance you indicate would be ideal, however the problem is the tail light inside the bar, I guess I could let the bar sit out a bit more and then there should be enough clearance to fit the hub inside the bar.

The bar should be strong enough to hold two wheels, if not I can always go to a 4mm wall. I have limited experience with wheel carriers, but I was going to try to simplify it a little. My question to you is whether it is really necessary to have a hub and bearing set up. Wouldn't a hub with a nylon bush be able to take the weight of the wheel and still provide sufficient smooth movement of the carrier?

I will keep your kits in mind, as they are very well designed and you have a good reputation and who knows I can always get wheel carrier kits from you and adapt them on my bar....it will save me a lot in labour time.
Hendrik. PM sent a couple of weeks ago - did you get it?

[Hendrik]

Hi guys
Sorry I have been flat out lately, so haven't been able to take any orders. I do have some time off coming up so will be able to take some orders. And I have replied to the millions of PM's I've been getting.

[Shylock]

Old thread but in case any of you are still bashing these out... Mine is a D2 V8 2001, Sydney-based, and could be tempted to invest in one of these if anyone here is interested. Pls pm me.

Any insurance/legality issues on these sort of things to be aware of?

ta,

D

[Disco Muppet]

Any insurance/legality issues on these sort of things to be aware of?


Insurance wise it's entirely up to you if you tell them or not, as it's not a modification it's highly unlikely they'll refuse you a claim based on it, they just won't give you any money if you don't list it and it's damaged.
Legality, should be similar to the above, it's not replacing any safety type component, and it's not got giant metal spikes welded to the sides so you should be fine :)

[sheerluck]

Insurance wise it's entirely up to you if you tell them or not, as it's not a modification it's highly unlikely they'll refuse you a claim based on it, they just won't give you any money if you don't list it and it's damaged.
Legality, should be similar to the above, it's not replacing any safety type component, and it's not got giant metal spikes welded to the sides so you should be fine :)

Not so clear cut, young Muppet. Read the small print on your insurance, as mine defines a modification as anything it didn't leave the factory with.

[Disco Muppet]

Not so clear cut, young Muppet. Read the small print on your insurance, as mine defines a modification as anything it didn't leave the factory with.

Must be a QLD thing :D
When I spoke to my insurer (AAMI) they said it was things that altered factory components such as ECUs, diffs, etc that would impact the way the car drives.
For example, my UHF, stereo, bar, winch, spotties, dual batts, etc are all classed as 'accessories', but my suspension lift is classed as a modification, and as such alters my premium.

[DR4GON]

Where are you situated, and are you still making these?

Broke my rear plastic number and right light assembly on a 2001 D2, so looking for something to decrease the distance from my rear wheel to my chassis. (Drove over a log, front half went fine but started a climb right after, so as my rear wheel dropped off the log, blam.)