Thread: XROX Front Bars

Originally Posted by Forged

I tried installing mine XROX bar yesterday and unfortunately i stretched a few of the existing crush can bolts I have new ones now thankfully.

Can i just ask those who have installed it, why do i have 4 3mm thick washers? Did anyone use these or just the existing ones on the mounts?

Also, has anyone found the XROX mounts to be slightly too big for the chassis rails? thats why i had to really wrench on them to stop them moving slightly.

If you're using the original 10mm bolts I'd be changing them for either 12mm or 1/2" high tensile ASAP...

Originally Posted by MR LR

If you're using the original 10mm bolts I'd be changing them for either 12mm or 1/2" high tensile ASAP...

Cheers mate, i used new m10x120mm high tensile bolts. When i install my steering gaurd i will replace them with m12x120mm.

My understanding of the certification process is that crash testing is not necessary.
This is from the importer I worked for importing US bullbars and submitting them to a licensed engineer who examined them to judge whether they conform to ADRs. They were then batch approved by the engineer. It cost about $1000 plus AFAIR.

The most important is no projections beyond the front of the bar, and that the loop or top rail of the bar cannot project past the bar itself, although I seem to recall that recently there is a change where it can project a small amount in front of the main bar. The other issues are shrouding of headlights and indicators etc.

Airbag deployment these days depends on an accelerometer AFAIK in the console of a D2.

I don't know the role of crush cans at the front but they may be to reduce damage to the chassis in minor crashes. They don't appear to have any switches which they would need to have a role in triggering airbags.

So if the manufacturer says they are ADR compliant it should mean that the design has been vetted and approved by an engineer, although it may of course mean that other similar bars have been approved and the new bar is for all intents identical except for the mounts. LOL

I recall my boss would tell customers that the bars were ADR compliant but not yet approved which I refused to say to customers.
Regards Philip A

The OEM "crush cans" are considered a "deformable structure" that may play a role in deceleration prior to and subsequent trigger of airbags (for switch based systems) or simply pedestrian safety as part of the larger structure.

What that means is you can hang anything off the OEM crush cans OR behind the line of their furthest deformation point and as long as the original "deformable structure" is there it's compliant as all original passing material remains.

So when I made my first winch cradle it was parallel flange channel on the OEM chassis holes but the front edge was back enough to "pass" the requirements. Then I made what was essentially a xrox vague copy out tube and it covered the steel backing "deformable structure" of the OEM plastic.

And yes the D2 has the accelerometer/decelerometer under the centre console. Used for airbags and pitch/yaw for ACE.