Fitting ARB D2a Sahara bar to D2

**DiscoDan** · 12th April 2009, 08:59 PM

I got my new bar just in time for the Easter break Thanks Adam

Anyhow I have seen a few questions on how to fit these up so I thought I would give the whole putting photos on and writing up a tutorial.

Please be gentle as it is a first for me

The start, remove the D1 bar off the front of the D2

Fit the crush cans from the new bar to the chassis rails

Take note of the grill and under light trim, these are the items the have to be cut to fit the bar to the car

Grill and under light trim removed, don't forget to remove the indicators first. This will also allow clear view of the screw that can only be accessed via wheel arc.

Bar fitted and tightened Let the trimming begin...

These show the areas to be trimmed, I used a jigsaw with a fine detail blade on it. Oh and I could have been a little tidier but time was running out and rain was coming in.

This shows how much was cut off, sorry I didn't measure it, it was fit then trim then refit trim etc, approx 5mm each re-trim

Grill and under light trim back on, small gap under bar and it all looks good

I now need to pull it back off and change to colour to black, My wife is not happy as she likes the deluxe bar over the Sahara bar, oh well it should grow on her.

So I hope this helps someone out and there might be more from me as the skills evolve. I need to do a snorkel next but waiting for the template I have ordered.

Danny

**dullbird** · 12th April 2009, 09:06 PM

nice work I would love to have a sahara bar on my D1

I think they are GREAT looking bars!!!
I actually dont mind the silver either.....BUT would look much cooler colour coded

**long stroke** · 13th April 2009, 06:27 AM

Very nice!!!

Just interested, did you run crush cans with the d1 bar fitted?, if so which ones??

CHEERS TIM.

**Pedro_The_Swift** · 13th April 2009, 07:18 AM

Nice one Danny

will arrange for this to end up in Projects and Tutes.

**DiscoDan** · 13th April 2009, 07:38 AM

I will post photos of the mod I did on the D1 crush cans, I decided not to chop them up too much as I do want to sell the bar.

There are 3 holes on a D1 crush can (2 together and 1 further in)and only two on the D2. The 1 further in had to be cut to separate the weld and then bent to miss the chassis mount. None of the crush section was modified and all that needs to be done is the side straighten.

The D1 bar did fit but had a few gaps where it didn't match the body work.(looks good in photos) It also stuck out a bit more than the D2 bar. The sides of the bar protruded into the wheel arch as well. But it was only on short term until I found a bar that I wanted (for the right price). I had it as a spare and didn't want to destroy the front bumper and factory nudge bar.

The other deciding factor was would it cause problems with the SRS in the event of an accident. Well that is what I told my wife

(that is why I bought the car "SAFETY" for 3 kids)

Originally Posted by long stroke

Very nice!!!

Just interested, did you run crush cans with the d1 bar fitted?, if so which ones??

CHEERS TIM.

**Sven_040** · 13th April 2009, 08:15 AM

Good stuff Danny, the bar looks better with your colour disco than it did with mine.
Have you mounted the aerial up yet? Cause that sort of gives a bit of protection to the headlight.

Adam

**trog** · 13th April 2009, 11:51 AM

i will let you take a peek at my guard for your template in exchange for your old lightforce's. need some soon as i get my new front bar in about a week providing i am not rained of work too many more times!

**dullbird** · 13th April 2009, 12:52 PM

Originally Posted by trog

i will let you take a peek at my guard for your template in exchange for your old lightforce's.

need some soon as i get my new front bar in about a week providing i am not rained of work too many more times!

**DiscoDan** · 15th April 2009, 11:56 AM

Originally Posted by dullbird

Don't mind him Lou, he is a Canadian

Longstroke here are the photos

The mod to the D1 crush cans is as per photos,

I cut the top so I could bend hole 3 out of the way

**dullbird** · 15th April 2009, 04:58 PM

Originally Posted by DiscoDan

Don't mind him Lou, he is a Canadian

Longstroke here are the photos

The mod to the D1 crush cans is as per photos,

I cut the top so I could bend hole 3 out of the way

I figured you must of known each other for such a generous offer

I mean how could you refuse

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