Page 1 of 2 12 LastLast
Results 1 to 10 of 13

Thread: Discovery 1 winch Bullbar Build

  1. #1
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0

    Discovery 1 winch Bullbar Build

    So i thought i put up a thread about the bullbar im building for my D1. I'm going for the competition style look. My D1 is a 1997 non aribag so i dont have to worry about any of that stuff.

    I've done a similar bar before and ive made a few changes to this to fix some of the flaws in the first.Anyway here's my model in 3d that ive used to generate the flat pattern and laser cut it out.

    4vl89A.jpg
    U2nOJh.jpg


    Not sure if going to do the headlight bars yet but i think i will so i can add the brush bars onto them. But i'll see how it looks when i get to them.

    So next step it to do layout and then laser cut them out.

    4YTo4E.jpg

    ftcaqy.jpg


    I should say at this point I'm using 4mm steel and bars will be 40nb 3.2mm wall. All areas have some form of gusseting and the winch tray is 2 layers so 8mm in that area. So once it's cut out6 time to fold it....
    1QEoUX.jpg

    Ejn7ZF.jpg

    And thats as far as i got today. So next up will be to tack some of the main frame together and test fit to the car. Hopefull i havent f'd anything up and it fits as it should.

  2. #2
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Sorry for not much updates been busy with work and family stuff. Made the main hoop for bullbar it turned out a bit too tall but bender requires 100mm of straight before 1st bend ive since cut 65mm out and looks better ill get some more pictures lates in the week.

    The main bullbar section is fully welded had some issues with bits not fitting correctly but that always the case when going from cad to real life.




  3. #3
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    A quick note it actually sits back further than it is in last picture i just didnt have it all the way on.

    Also been mocking up a water tank that mount inder floor between cjassis and sills. Seems to fit good so ill draw them up and decide whether i make them fuel or water.

  4. #4
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Made some progress today. Was supposed to do some yesterday but a flat battery prevented me from driving to work..

    Anyway got the wings done and the 3rd bar to add some additional strength. Also sort of done 1 headlight bar i think it looks ok will hopefully get onto the 2 drivers side on monday. Was considering infill panels between bars before but ive canned that idea now. Without the 50mm that a body lift adds to main cradle i dont panel be needed.



    As you can see i cut 65mm out of the main hoop and it was perfect . Looks more balanced at this height.






  5. #5
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Heres another picture of the 3rd bar. On the 1st bullbar i did for my mate didnt have this one and he bent it pretty easy so hopefully this add some more strength certainly feels solid with it.
    It ties into the middle of the bends under indicator



    This is the headlight bar. Would have liked it across further but put it too close to body so it is what it is.


  6. #6
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Finshed tacking the bar together. Got the drivers side headlight bar on and some plates to cover gap between bars and headlight. Also welded on some tabs for aerials



    Now ive just got to weld it out then send it off to powdercoaters




  7. #7
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    So bar is welded and dropped off to powdercoaters this arvo. I test fitted winch and probably lucky i did i had to make clearance for the handle in the emd it was easier to cut whole section out as itmade getting winch in easier. Bent some some flatbar arpund edge to stiffen it back up





  8. #8
    Join Date
    Aug 2016
    Location
    Brisbane
    Posts
    240
    Total Downloaded
    0
    Nice work Pub!

  9. #9
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Thank s mate got it back from powdercoaters today must not be busy to have it done in 2 days.

    Anyway haven't put it on yet as i'm just putting in a daul battery setup and putting on some new terminals. So i can wire up winch. Thought id have till end of week to get it done obviously not.

    Anyway mandatory picture. Also got the eyelets and bow shackles done black whilst it was there. Now i think about it should've got the fairlead done too





    And picture i took of daul batteries and new clamps i fitted this arvo


  10. #10
    Join Date
    Nov 2014
    Location
    melbourne
    Posts
    171
    Total Downloaded
    0
    Fitted winch and bar tonight. Still have to run wiring for winch but theres enough room to reach from underneath.
    Think im done with bar. I might make a flip down license plate for middle currently plates mounted on wing side.
    Probably do brush bars and update this thread later


    Pictures.






Page 1 of 2 12 LastLast

Tags for this Thread

Bookmarks

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Search AULRO.com ONLY!
Search All the Web!