New D2 Custom rear bar - Progress

[Psimpson7]

Hey All,

Decided that I didn't really like the off the shelf options and as we needed one due to a bumper / rock interface, I have decided to make one!

the top face, rear and both sides are all 1 piece of steel. All 4mm for now. Currently just tacked together for checking fitment, which seems to be perfect! which is a relief! :)

It's only bolted on lossely here so will lift up a fraction more.

What do you reckon?

https://www.aulro.com/afvb/images/imported/2011/02/665.jpg

https://www.aulro.com/afvb/images/imported/2011/02/666.jpg

https://www.aulro.com/afvb/images/imported/2011/02/667.jpg

https://www.aulro.com/afvb/images/imported/2011/02/668.jpg

https://www.aulro.com/afvb/images/imported/2011/02/669.jpg

https://www.aulro.com/afvb/images/imported/2011/03/1047.jpg

[Larry]

Certainly looks good.:TakeABow:

If only I had the skills.:(

[zuno555]

wow, will look like a factory bar when finished!

Did you make this all at your home? How did you bend the 4mm so accurately and cleanly, looks great!

[GEK064]

I reckon I want one!!!! How do make such a thing? How do you cut it, shape it etc with such precision? All at home? I read and see such amazing things coming out of people garages on this forum - I'm in awe ( and envy for those skills)! Well done!

[clubagreenie]

Thats the first thing I've seen i would actually buy!]

One thing to change. Make the side wrap arounds horizontal (or have an option at least) to . gain some more clearance and 2. I'll be cutting the lower section of my rear quarters back to raise, as I used to do on the series (cut and fold above the top of the rear cross member)

But the only question is how much? std lights?

Alternately consider selling the plans for a nominal fee. I sell all my adaptor plate and flywheel designs for $25- via ebay and only need to email the files and rake it in.

[Psimpson7]

Thanks All,

Ok, how I did it, but I am lucky to have access to some cool toys for this stuff as you will see in a second

It started life like this:

https://www.aulro.com/afvb/images/imported/2011/02/662.jpg

From there, after a lot of measuring I modeled it up using CAD.

https://www.aulro.com/afvb/images/imported/2011/02/663.jpg

That then allows me to flatten the sections out:

https://www.aulro.com/afvb/images/imported/2011/02/664.jpg

I then sent these to a laser cutters who cut and folded them to my files.

The top pic in my original post is what I picked up today straight from them.

Other questions.

Yes, it uses std lights.

i wouldn't really be able to sell the plans as that would involve me giving out the cad files for lasering.

Parrallel sides would be easy as an option.

We were really keen to get a standard looking steel bar, so I am glad that is how people are seeing it :)

I wont go into costs as I am not a vendor on here, and I dont want to upset anyone or get it moved to market place alerts.

At the moment its just a 1 off for us, but that may change, once I have got it 100%

Not all smooth sailing though as I have messed up the light brackets tho so need to get those recut!

Cheers
Pete

[bryan]

Wow a fantastic result!

Not being a CAD person what CAD package did you use?

and did you get someone to do the bending for you or were you able to do this at home too?

Bryan.

ps: I for one prefer the sloping sides as it looks more "stock".

[bryan]

Sorry. I misread. You said the laser cutter did the folding as well.

Wonderful result!

Bryan.

[weeds]

nice, bit hard to tell from the angle the pic was taken from but does the bottom front edge hang a little low

[Psimpson7]

Some better pics:

https://www.aulro.com/afvb/images/imported/2011/02/635.jpg

https://www.aulro.com/afvb/images/imported/2011/02/640.jpg

https://www.aulro.com/afvb/images/imported/2011/02/641.jpg

[cal415]

Awesome job! I should really learn to use cad and find a laser cutting shop haha would make things easier... I keep seeing more and more builds using methods like this and it just comes up so neat and professional, who needs to by a kaymar when you can make something like that.

[weeds]

Some better pics:

https://www.aulro.com/afvb/images/imported/2011/02/635.jpg





all good, that pic looks way better

[Nova]

Awesome looking bar. Any thoughts on LED replacement lights?

I would be very interested if you decided to make and sell them.

Cheers,
Nova

[awabbit6]

That looks brilliant Pete! Well done!

What are the slots either side of the lights for? Light guards?

[Psimpson7]

Thanks all.

Welded up most of it this evening - Did it in short sections, and managed to get no distortion:

https://www.aulro.com/afvb/images/imported/2011/02/628.jpg

https://www.aulro.com/afvb/images/imported/2011/02/629.jpg

Paul, the little slots were for the light mounts that fit inside the bumper, but I got those wrong, and tweaking them hasn't resulted in a decent result, so I need to rework how they are going to work.

Wont be much progress on this for a few days or so now, but hopefully i can get back on it next week some time.

LED lights would definetley be possible (and probably far easier to mount!) but I dont really like the look on a stdish car

update this again when I get further.

[BMKal]

That looks brilliant Pete.

Probably the closest to the original look that I've seen. Hadn't thought of using CAD like that and having the bar cut and folded from a single sheet. You've given me something to think about.

[clubagreenie]

I want std lights, horizontal lower sides, and an email to ppal money to you.

[damo_s]

Wow, looks fantastic!

Are you going to get it powder coated?

[Psimpson7]

Ok, got some more done on this over the weekend. Nearly ready to send for blasting and most likely galvanising then painting.

https://www.aulro.com/afvb/images/imported/2011/03/1053.jpg

https://www.aulro.com/afvb/images/imported/2011/03/1054.jpg

https://www.aulro.com/afvb/images/imported/2011/03/1055.jpg

[AussieAub]

Looking very good!
Very nice clean lines there mate, but you need some "extras" for that standard look! :D :cool: ;)
I preferred the standard lights over LED's too, much nicer on a more standard looking motor. :angel:

http://www.aulro.com/afvb/attachments/discovery-2/25458d1273912420-new-rear-bar-mutts-nuts-11.jpg

http://www.aulro.com/afvb/attachments/discovery-2/25471d1273976210-new-rear-bar-mutts-nuts-13.jpg

(more pics and stuff here: http://www.aulro.com/afvb/discovery-2/105082-new-rear-bar-mutts-nuts.html#post1252443)

Cheers,

[Psimpson7]

That's very nice Kieren. Hadn't seen that before - Nice work.

Ive had a couple of comments re catching the lower rear corners:

So i may tweak it slightly:

https://www.aulro.com/afvb/images/imported/2011/03/1049.jpg

https://www.aulro.com/afvb/images/imported/2011/03/1050.jpg

[clubagreenie]

Still need to know when the plans will be available....

[greg smith]

That is something I really need,my plastic one is cracked from the knocks from boat and box trailer and noticed the other day a crack above the l/h tail light,right through that one of yours aus aub looks the ducks as well:D

[isuzurover]

Very nice work Pete.

[mattg]

Nice tweak Pete.

This is a cracker project

I was thinking about integrating a checker plate step into the actual bumper so the kids can use it to clime into the back.

I have also thought about mounting a high lift jack on the bumper. Might work well on this bumper Pete.

Cheers

Matt

[Tombie]

How's this coming along???
:D

[Psimpson7]

Its finished and is being painted this weekend. :)

Photos early next week.

My exploding gearbox slowed progress slightly

[Psimpson7]

Ok, I have it fitted after painting! Sorry for the delay in the update. The 90 repair took priority.

Just need some new plastic finishing trims now as both of ours are damaged / jammed in place:

Will get some better pictures over the weekend.

https://www.aulro.com/afvb/images/imported/2011/04/497.jpg

[clubagreenie]

But when can we buy the plans???

[mattg]

Hi Pete

That is Awsome. even better painted.

What did you paint it with?

cheers

Matt

[Disco Driver]

Hi Pete,

I know it's been over two years, I was just wondering how this has worked out for you? Are you/have you been fabricating any more?

I now need to replace mine...:(

Cheers, Jayden

[alex_bg777]

This is my custom rear bumper

http://www.aulro.com/afvb/attachments/discovery-2/88525d1418889605-new-d2-custom-rear-bar-progress-lr-disco-2-hd-rear-bumper_2.jpg


http://www.aulro.com/afvb/attachments/discovery-2/88526d1418889668-new-d2-custom-rear-bar-progress-img_3698.jpg


http://www.aulro.com/afvb/attachments/discovery-2/88529d1418889795-new-d2-custom-rear-bar-progress-img_3736.jpg


http://www.aulro.com/afvb/attachments/discovery-2/88527d1418889709-new-d2-custom-rear-bar-progress-img_3726.jpg


http://www.aulro.com/afvb/attachments/discovery-2/88528d1418889750-new-d2-custom-rear-bar-progress-img_3732.jpg











PS




I can't make pictures bigger. Can you help me?




***photos resized by moderator