Stooge's D1 Brush Bar install

[Cap]

I have sourced a D2 (yes thats right, a D2) brush bar from JC. Brush Bars have a reputation of rusting away from the mounting points, and all i can say is thats 100% correct. I removed ALL the powder coat paint, and guess what, plenty of rust under the paint even tho externally it looks clean.

So, those with brush bars, please check this because you wont see the poblem until its under the Rover!

So, a few pics of the bar and it positioned on my d1 to measure up and design mounts for it :)

https://www.aulro.com/afvb/images/imported/2009/08/358.jpg
Brush Bar with paint removed, reasy to cut off chasis mounts.

https://www.aulro.com/afvb/images/imported/2009/08/359.jpg
Brush bar rust at mount weld :o

https://www.aulro.com/afvb/images/imported/2009/08/360.jpg

https://www.aulro.com/afvb/images/imported/2009/08/361.jpg
Brush Bar on D1

https://www.aulro.com/afvb/images/imported/2009/08/362.jpg
Template design ready to take to engineering shop to cut out using 8mm flat bar

Ill keep updating this thread when I have the components ready to install :)

[2_door]

that actually looks good Carlos....I was thinking you would need to cut the wings off and just use the hoop but I think the whole wrap around thing looks okay.

do you think the wings will be strong enough to withstand some offroading :confused: or would they just fold back and damage the body :(

[Scouse]

Unfortunately, the ends offer next to no protection at all. The bar is virtually made of exhaust pipe & the ends often fall off after a few 1000km of rough roads.

They do make a nice spot light mount though :).

[justinc]

that actually looks good Carlos....I was thinking you would need to cut the wings off and just use the hoop but I think the whole wrap around thing looks okay.

do you think the wings will be strong enough to withstand some offroading :confused: or would they just fold back and damage the body :(

Hi Mark, quick Hijack, waved at you today passing the Domain on our way to the airport, those Simex are LOUD, travelling the opposite direction in the mobile lounge room (Lexus) with the 1/4" thick windows up I could hear them:o

JC

[Cap]

I recon if I smack the side bars against the panel chances are I would be hitting the panels anyway. Also, I will be adding another mounting bracket up the pipe which will bolt up against the bumber, for added strength.

I know this is NOT a bull bar, but more a dress bar. I also dont want to do any further hard stuff, last experience was enought for me.

[Chucaro]

Looks nice but the bar blocks the view of the number plate.
Is that legal in Tasmania?

[Cap]

Its only positioning, I will move it up once the bar is just about to be put on.

[2_door]

Looks nice but the bar blocks the view of the number plate.
Is that legal in Tasmania?

no, but I am sure Carlos will find somewhere else for it :D maybe put them both on the back :twisted:

[Cap]

DId some more work on the brush bar. I cut out the bottom brace that was rusted out and re-welded another thick wall tube. This will allow me to weld the chasis mount to the bar with a solid weld!

It was damn tricky welding a 3mm wall thickness to the 1.6mm or so wall thickness of the bar. But I eventually had the right amps and managed to do it, although not the prettiest weld it will certainly hold! :cool:

https://www.aulro.com/afvb/images/imported/2009/10/422.jpg

Next I need to fab the chasis mounts - JC need to organise something with you.

[2_door]

looking good Carlos :D

[justinc]

Looks good, Give me a call. We are all sick at the moment so no chance of a dinner etc:(


JC

[Cap]

Yes its coming along nicely 2_door...

Sorry to hear you all sick, but thats how it goes! Mind you, get it now, over and done with ready for the good weather :)

[Cap]

I got the brakets made up from an engineering shop out of 10mm plate. Not a bad job, paid $120 for the pair.

So pictures tell the story of what I did today:

https://www.aulro.com/afvb/images/imported/2009/10/20.jpg

https://www.aulro.com/afvb/images/imported/2009/10/21.jpg

https://www.aulro.com/afvb/images/imported/2009/10/22.jpg

https://www.aulro.com/afvb/images/imported/2009/10/23.jpg

https://www.aulro.com/afvb/images/imported/2009/10/24.jpg

https://www.aulro.com/afvb/images/imported/2009/10/25.jpg

https://www.aulro.com/afvb/images/imported/2009/10/26.jpg

So overall happy with it, paint is the usual KillRust brand that I have used many a times in the past.

Will be putting another coat on and then pop it on the Disco, and finish the spotlight install :) :)

Then she's all done!!

[justinc]

Looking excellent, will it be on today or tomorrow?

JC

[Cap]

Ill put it on next weekend to give me another chance to recoat. Re-coat times are 16 hours apart :(

[Cap]

Finally finished the bar, although I did stuff it up on the paint job as I can see lots of smeared paint... but thats what happens when you got no room!! :(

So here is the final pics, with spotties on but not wired in... will do over weekend :)

https://www.aulro.com/afvb/images/imported/2009/11/1185.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1186.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1187.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1188.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1189.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1190.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1191.jpg

https://www.aulro.com/afvb/images/imported/2009/11/1192.jpg

[2_door]

looks good Carlos.

are those larger holes to be used as recovery points :confused:

[Cap]

Yep they are the recovery points to replace the existing ones I have. It wont be an issue with 10mm plate!

[agrojnr]

Nice work there:cool:

Can't beleive they charged you 120 for them thought:(

When I get there I will hopefully get done there and have a look for myself:D

So if any of you tassie blokes needs some plates cut let me know and I will see what I can do:angel:

Adam

[Cap]

Thanks for the offer Adam. Yeah it was a bit more than I thought, and JustinC had offered to cut some for me, but the bloke is waaaaaay to busy running a business so I thought ill just leave him alone :D

Let us know when your traveling down south mate ;)

[agrojnr]

Mate I will be there (in tassie) for christmas and new years visiting my parents and I am planning on going to hobart for a weekend

Adam

[Discovering NZ]

Thanks for your posting Stooge
I found a D2 set over in NZ at about 1/3rd the price of the D1 bar :), so brought it and followed your plan of making the bar mounting brackets and firmly attaching the bar, rather than using the standard brackets.
I also had an extra bar attached to the wings and bolted back to the standard bumper, just to add extra stengthening of the wings. See attached photo for final result. Not sure if my paint job is as good as yours though...
road tyres on in the photos...

cheers and may thanks for the original posting
Greg

[Cap]

Hi Greg,

Funny seeing another D1 with the same bar! I can see the lower bar where the chassis mounting brackets are have also been modded. Nice work, I think the D2 bars look much better than the D1's.

As for the paint job, its amazing how a photo can hide imperfections. I painted it with mat black Killrust paint, with a brush, and you can see the paint runoff where I over painted :angel: