Thread: Defender Sliders. Home made and Cost effective

After pricing some sliders from different places i decided to make my own.

I copied the design from Camel Mark, His Defender has a nice strong set made from 100x50x3mm RHS.

Mine are the same dimensions, but i mounted mine in a different fashion.

I wont bore you will all the details on how long it takes and problems as the 1st set you make are the hardest.
But i will tell you how i did it.

I 1st removed the original sills and took the measurment of them. 1860mm from memory
i then cut my RHS 6mm shorter than this to allow the endcap steel to be welded on and it should then be the same size. I cut the RHS on the same angle as the original sills and then 60mm down i cut it back at a 45deg angle. This makes it neater and slide over things better. I then welded plates on the ends and cleaned up the welds.
Sliders complete.............. nearly

Mounting..........
Well here is the part some will go different ways about.
I looked at the bearmac and others and they only have a front tag to the front outrigger bolt plus the rear mount. Strong enough, but i wanted to make sure i could jack off mine.
So i used a 40mm Angle at the front and cut it flush with the body, at a later stage if the sliders move i can plate the bottom of this to the outrigger.
Then i used 80mm wide offcuts of the RHS and cut them to the correct body length. middle one was 38mm, rear 72mm and the RHS was 15mm difference.
How do they mass produce these??? when there is such a difference in dimensions?
I bolted both on with 2 bolts each in 10mm and used Nylocs to stop them undoing. Bolts are High tensile.
I then used the hoist i was working on to hold the sliders on the body and i G-clamped the slider to the mounts and then checked again the measurements.

Out came the Mig and i Tack welded the Slider onto the mounts. I then released the G-clamps and the hoist.
I then unbolted the mounts and slid it off the Defender.
Then i fully welded all the mounts and cleaned up the welds and cleaned off burs ect of the holes.
Then the part we all dred.... will it fit again.
YES Perfect. Very tight fit.

Now all i have to do is paint them.
I'm chosing Flat black at this stage but long term might paint them a different colour.

The only thing i have to do is drill a hole in each end for the flare to mount. But im toying with differnt ways as i have a master plan for that large capacity of RHS......

AIRTANK. Both sides are Airtight to my knowledge. so i'm going to weld some fittings on and when i install the compresser it can use them and tanks.

As for the cost involved. Materials about $120-$140 and labour was about 14 hours unpainted.
Next set i think i could do in about 8 hours.
So if you have to pay someone else to do them then $500 is a cheap set.

Hear are some pix. More to come and the lot are in my gallery.
http://www.aulro.com/modules.php'set_album...=view_album.php

I have a ARC and a Mig i borrow. Arc is good for heavy stuff

Spend the $800 and get a Mig