D2 custom Bullbar

[bluelightdisco]

G'day all
just finished building a Aluminium bullbar for my D2 and i was quite impressed with the result so was wondering what you guys think , the mounts are 12 mm ally and the bar itself is 5mm plate, and also the hoop is 60mm dia by 5mm wall thickness so its nice and solid. Hoping to colour match the bumper to the car and polish the hoop but first add some air intakes and fog light holes. Thanks
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[LandyAndy]

Looks good.
Make sure you post pics after paint.
Well done.
Andrew

[bluerazor]

Well done. Nice job but shame it hides the "Land Rover" decal :mad:

[midal]

Nice looking job. Given that you made it yourself, is it airbag compatible?

Cheers
Mick

[bluelightdisco]

Nice looking job. Given that you made it yourself, is it airbag compatible?

Cheers
Mick

i incorporated the crush cans into the design by leaving them in thier standard place in front of the chassis rails and and placing the bullbar mounts on the inside of the chassis rails and then placing a piece of 3 inch 6mm walled box section cut at a 45 degree angle welded onto the bullbar mount directly in front of the crush can so in theory if the bull bar moves backwards more than 20 mm it will start to push the crush cans back into the chassis rails.
forgive the crappy tech drawing my auto cad drawings wont upload for some reason
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[DiscoDan]

I like the bottom section however I think I would prefer a lower and wider hoop. Maybe following the grill shape more.

Did you cut the grill?

How is the weight?

Can you mod it to fit a winch?

Not sure how you would you could get it certified for air-bags but if you could and the price was right I could see you moving a few. Cheap good looking bullbars for the D2 are few and far between

Cheers
Danny

[midal]

i incorporated the crush cans into the design by leaving them in thier standard place in front of the chassis rails and and placing the bullbar mounts on the inside of the chassis rails and then placing a piece of 3 inch 6mm walled box section cut at a 45 degree angle welded onto the bullbar mount directly in front of the crush can so in theory if the bull bar moves backwards more than 20 mm it will start to push the crush cans back into the chassis rails.
forgive the crappy tech drawing my auto cad drawings wont upload for some reason
214672146921470


It's a good job.....you've put a bit of thought into that. Well done. By the sounds of things there may be some prospective customers for you.

Cheers
Mick

[bluelightdisco]

I like the bottom section however I think I would prefer a lower and wider hoop. Maybe following the grill shape more.

Did you cut the grill?

How is the weight?

Can you mod it to fit a winch?

Not sure how you would you could get it certified for air-bags but if you could and the price was right I could see you moving a few. Cheap good looking bullbars for the D2 are few and far between

Cheers
Danny

yeah i thought the hoop was a bit tall my self until i considered the height of our local skippy's (4.5 ft is a little one). the press bender i have access to can only bend to that radius and that size pipe maximum i wanted 76mm pipe but the bender would not fit it, it can be done but would have to outsource to other companies that have a mandrel bender.
also i did not have to cut the grill whatsoever just made the bullbar wrap around it and i have not officially weighed it yet but i can pick it u my self easily one handed so at a guess i would say around 18- 25 kg and as for modding it for a winch i have to size up a few different winches and see how they mount up i know the 12mm ally mounts are overengineered for this job so im not worried about them and the mounts are held on by 1/2inch high tensile bolts that pass through the ends of the chassis rails and the ends of the crush cans so that is all fine, its just making a cradle to fit in the bar which i would try to make out of ally just to keep the weight down and modding the front for a roller-fairlead but i would pre-fer the hawse fairlead and is smaller and i love the plasma rope its tops! and as for certification i am going to see an engineer with my blue prints to tell me what he thinks , this was a rush job as my standard bumper was smashed by a skippy and could not afford to run around with an exposed RAD/AC/INTERCOOLER/ETC

[Basil135]

Looks the goods... :D

You have done well...

Add me to the list of possibly interested prospective customers should you decide to make any more...;)

[DiscoDan]

Mate well done, I can see from your reply you have put a lot of thought and effort has gone into your work.

Great work, sit back and reap the rewards