Brooksy's rear bar

[brooksy]

Hi fellas, as promised I have built a rear bar for my D2. It isn't finished as I haven't fitted reverse lights & bracing for the sides. I am also going to be welding on recovery eyes in line with the chassis. I had to quickly paint it with some spare junk that I had in the cupboard as I had some people who are interested in me doing some work for them in Hervey Bay once I open my new business up there in conjunction with a friends 4wd accessories shop. My business will be "CUSTOM 4x4 FABRICATIONS". As it turns out I have 3 jobs booked when I get there. I am already building 2 rear bars for D2's & 1 set of R/Sliders for people in Brisbane at this stage in my Garage with limited tooling & ROOM !! But I just can't say NO. Next time I post I should have a skid plate attached to it.







I will be adding a swing out wheel carrier, hi-lift & light to it when I get the chance. I will also post up progress pics if anyone is interested while I build the next bar.


brooksy

[Winaje]

Looks good, got a price?  Weight, etc...?

[brooksy]

They will be around $1,000 mark with the wheel carrier about $1,500. If I can intergrate the tow point & get a Class rating it will be about $150 extra. Remember I haven't finished the bar you see at the moment. I haven't got a weight yet although 1 person can pick up & fit it yourself quite easily, I will be taking it off this weekend to test fit on another Disco that I am building 1 for so I will weigh it then & get back to you on that.
It is a lot cheaper than a Kaymar with better clearances by a country mile !!!!


brooksy

[BGLandy]

Looks great, one of the best I've seen so far.
Will having the original taillights fitted into the bar be an option?

I have the 1999 model where the indicators are located
in the rear bumper.

Tim W

[brooksy]

Looks great, one of the best I've seen so far.
Will having the original taillights fitted into the bar be an option?

I have the 1999 model where the indicators are located
in the rear bumper.

Tim W

I am totally flexible in design. To fit original L/R lights I will have to make the bar out of 100x100 RHS instead of 75x75 which means it will be 25mm longer & lower......but "WHY" keep L/R lights....TOO EXPENSIVE to replace. I have decided on the lights I will use & will order a few sets this week. They are 124mm long x 39mm high & 11mm wide LED lights. They are single units, reverse, indicator, & brake. I only need the reverse on mine & the bars I am building on a '99 & '01 will have the indicator lights as we have all agreed that the so called red fog lights are not required. I have basically finalised my design for a wheel carrier which will be able to fit up to a 35" tyre. I have a new design drawn up on some R/sliders which will have 2 x 25mm dia. nerf/foot hold/ hi-lift points adapted into the slider. I have orders for both the wheel carrier & 2 on the sliders based on drawings already.


brooksy

[brooksy]

Here is a couple of pics of the test bar on a friends Disco & some of the rear quarter cut & drill marking for bolts.

P.S - don't you just love working on mates muddy rigs  8O  8O




This is the original bar that is from my D2 that will be used as a test for fitting & will have the side braces bolted on & an additional centre bolt on brace once the wheel carrier is fitted for extra strength & for future tow point adaptor.



This is a pic of the rear quarter cut with removed section on driveway & a close up.





You gain 140mm clearance behind the wheel, 155mm at the corner & at the bottom of the bar at contact point it is 80mm shorter. That's a LOT more clearance !!

brooksy

[simon_arch1]

Brooksy - any chance of building in a replacement for the "bumperettes" that sit above the original bar on each rear corner - ie. some steel that goes around the corners to cover up where the bumperettes always fall off and get knocked off - I've even seen them knocked off vehicles that have steel bars on!

Simon

[brooksy]

Brooksy - any chance of building in a replacement for the "bumperettes" that sit above the original bar on each rear corner - ie. some steel that goes around the corners to cover up where the bumperettes always fall off and get knocked off - I've even seen them knocked off vehicles that have steel bars on!

Simon

I don't see a problem with that, wouldn't be difficult & would probably make the corners more robust. It would probably take a bit of time to radius the top edge so I would suggest a 20mm x 45 degree bevell along the top edge & corners would look best.


brooksy

[brooksy]

Some more pics









Their are a couple more pics in my Gallery


brooksy

[BGLandy]

Hello Brooksy, the reasons for keeping the original lights
are, I already own them, don't have to change the wiring, don't
have to wrangle with the authorities over the legality of them
and fitted to you rear bar breaking them should be a thing of the past.

However having said that I quite like the look of the lights you have chosen for the rear bar.

Tim W

[brooksy]

Hello Brooksy, the reasons for keeping the original lights
are, I already own them, don't have to change the wiring, don't
have to wrangle with the authorities over the legality of them
and fitted to you rear bar breaking them should be a thing of the past.

However having said that I quite like the look of the lights you have chosen for the rear bar.

Tim W

Not a problem, the lights I will be using are ADR approved LED lights that are shock & water proof.

brooksy

[CAL415]

Gday Brooksy,
Does your rear bar mount to anything at the rear of the wheel arch or are those front sections only held from the rear section of the bar?
Thanks,


Mick.

[brooksy]

Gday Brooksy,
Does your rear bar mount to anything at the rear of the wheel arch or are those front sections only held from the rear section of the bar?
Thanks,


Mick.

Hi Mick, I have been busy lately fabricating gear for customers non stop the past 3 weeks so I haven't taken any pics of my L/R bars. The sides have brackets that are behind the 75x25 RHS that bolt onto the bar & then bolt threw the bracket that is on the chassis that is used for the tow hitch so I am using original points on the vehicle. I also have a tab that screws into the inner guard of the rear wheel arch to secure the rear quarter. As a whole it is very rigid & robust, almost bullet proof. I have 2 customers that are "Test Pilots" for the L/R bars & sliders so I will have in the field feed back & they will let me know if adjustments need to be done.


brooksy

[simon_arch1]

Brooksy - do you have a final price on your rear bar yet?  With lights?

Simon

[brooksy]

Brooksy - do you have a final price on your rear bar yet?  With lights?

Simon

Hi Simon,
I have just replied to your PM.
If you want the bar complete with lights & powder coated in Satin black they will cost $1,300 plus freight. I am currently doing all freight at half price. I can give cutting instructions for the rear quarters if required.

brooksy