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


Brush Bar with paint removed, reasy to cut off chasis mounts.


Brush bar rust at mount weld




Brush Bar on D1


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 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 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

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 maybe put them both on the back

[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!



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

[2_door]

looking good Carlos