D2 Custom Rear Bar

[discotek]

Okay fellas, I had a rush a blood and conjured up a rear bar for the D2.

Problem - Plastic bar ripped off twice, rear lights left hanging on numerous trips. Rear quarter damage on a recent trip to the Springs, Warwick.

Solution - A light weight steel rear bar. Not designed to handle a snatch (tow bar assembly still in place) or to be used with a high lift jack. (I can use the bull bag or use the high lift on the sliders)

Outcome - 2mm steel rectangular (100mmx50mm) plus other bits. Borrowed ideas from the USA (www.discoweb.org (http://www.discoweb.org))

New Skills - got handy with the grinder to cut bits off the rear quarters and can now sort of weld with the archy.

Pics:


https://www.aulro.com/afvb/images/imported/2008/11/347.jpg

After welding practise for a week, finally got the project going.

https://www.aulro.com/afvb/images/imported/2008/11/348.jpg

Had to spot weld the rear quarter guards on, while the bar was on the car. Then take off, weld on with gussets and refit.

https://www.aulro.com/afvb/images/imported/2008/11/349.jpg

After a couple of fitups on the D2 the spray can came out.

https://www.aulro.com/afvb/images/imported/2008/11/350.jpg

Finally got the finished rear on. Used 4 M12 bolts via the 2 standard bar brackets. Weighs only 10 or so kg's. Fitted with LED indicator lights. Added some non-standard mud flaps from Repco. Here's a few more pics...........

https://www.aulro.com/afvb/images/imported/2008/11/351.jpg



https://www.aulro.com/afvb/images/imported/2008/11/352.jpg

Obviously the original designers may be less than impressed. But it should be more forgiving on the track.

Hope this inspires a few more frustrated steel fabricators.

[harry]

hmm, that looks good,
do you mind if i copy some of your design, got the same problem on the tracks.

[cucinadio]

mate nice work ......gives a really nice line to the rear from the side profile ...and will take the nocks a lot better than the latter .

cheers

[Slunnie]

Well done! :cool:

[sadbenn]

good on you, now you've really gone and done it.... guess who wants me to get my lazy butt into gear to do the rear bar ie (copy yours) cause she has ripped our lovely plastic piece of crap off now twice....plus those bloody rock sliders... lots of work to be done, how bout a hand or directions, will have to purchase the metal... looks like a long weekend job... with a few beers too...
looks good, job well done.

[Utemad]

Looks great. Well done.

[harry]

i presume the sliders are dranged ones?

[discotek]

Feel free to use any ideas here harry. Oh yea and dranged did supply the sliders.

[discotek]

Sorry about putting the pressure on Sadbenn. Happy to share any details on this project. Will catch up you at Kilkivan next weekend.

[cucinadio]

i just cant stop comming back to this thread for some :angel: stupid reason.....really nice job disco :BigThumb:

[discotek]

Thanks mate. Glad you like it. Can't wait to get into a few wombat holes etc and checkout the clearance. Doing a trip next weekend.

[Redback]

Great looking bar, very similar too mine, one thing is that if you have only got it mounted to the standard Disco 2 mounts, if you come down on the bar they will bend, they aren't very strong and they bend very easy, i elongated the the bolt holes on my bar so it reduces the chance of bending the mounts in the below pic, until i get the chance to strengthen the mounting of the bar.
The bar moves, rather than bend the mount.

https://www.aulro.com/afvb/
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/

Baz.

[discotek]

Nice looking bar Baz. The standard mounts on the d2, do look a little on the light side. I used 4 m12 nutserts to get a flush fit of the bar to the mount, to maximise the exit angle.

There's a couple of strengthening issues I still need to address. The rear quarter guards could do with a strut to the chassis on each side.

As is though, it should beat plastic.

What gauge steel section did you use on your job ?

[Redback]

Nice looking bar Baz. The standard mounts on the d2, do look a little on the light side. I used 4 m12 nutserts to get a flush fit of the bar to the mount, to maximise the exit angle.

There's a couple of strengthening issues I still need to address. The rear quarter guards could do with a strut to the chassis on each side.

As is though, it should beat plastic.

What gauge steel section did you use on your job ?

Yes they are weak and are a bugger to get bend back to the original so the bar is level

It's 100mm x100mm x 3 or 5mm box, it's very strong, only ever bent the mounts, i have since cut the rear quarters to match the bar, i go to places like Appin and the Watagans where the tracks are steep and have steep drop offs that require good departure angle (D2s lack this as you know) so a bar like ours was needed;) i was sick of damaging the rear bar and rear quarters:D

Baz.

[glenn82]

discotek how many hrs went in to making the custom rear bar?... what did it cost u ?
i realy think it looks great and would look even:p better on my D1

[cucinadio]

Great looking bar, very similar too mine, one thing is that if you have only got it mounted to the standard Disco 2 mounts, if you come down on the bar they will bend, they aren't very strong and they bend very easy, i elongated the the bolt holes on my bar so it reduces the chance of bending the mounts in the below pic, until i get the chance to strengthen the mounting of the bar.
The bar moves, rather than bend the mount.

https://www.aulro.com/afvb/
https://www.aulro.com/afvb/
https://www.aulro.com/afvb/

Baz.



baz really nice bar mate looks sweet in the painted pic ....do you have pic after you cut the guards?


cheers

Matt

[McDisco]

Nice work! I have a similar bar on mine and have been thinking of trimming the rear quarter panels too...might have to crack out the grinder....

Angus

[discotek]

Hows it going Glenn82.

Spent about 20 hrs on the rear bar job, but I don't have a trade, just a DIY tragic, so needed to go slow.

Steel - $80
Paint - $15
Bolts / Nutserts - $30
LED lights - $60
Consumables - grinder disks and welding rods - $20
Mudflaps - $30

[spudboy]

I love a nice bit of metal work.

Also - You forgot to say how many dollars of beer you took to complete the job :D

[Redback]

baz really nice bar mate looks sweet in the painted pic ....do you have pic after you cut the guards?


cheers

Matt

Matt, i think discotek has cut his far better than my job, his looks more professional.

BEFORE and the reason i did the cut
https://www.aulro.com/afvb/
AFTER
https://www.aulro.com/afvb/

Baz.

[LR25TD]

Have you tried it out in anger yet .If so where you happy with your work.
If I could knock one up like that I would be stoked.In fact I am gunna have a red hot go at it,
Im Inspired. Cheers