ARB Bull Bar modifications

MuddyMudskipper

Camp Ninja
R_Lefebvre said:
Muddy, that's fantastic info, thanks. I haven't been able to get that much detail at any of the specialist Disco Websites. ;)

Sounds like the only real problem is the slotted holes, which isn't an insurmountable problem. How much material is there on the frame horns ahead of those existing bolts? Enough to drill and install another set of bolts?

About an inch 1 1/4' on the lower bolt forward bolt hole and about 3/4' on the upper forward bolt. There would be enough room for one, comfortably.

R_Lefebvre said:
Alternatively, install it and get is set up. Then remove one bolt, and weld a washer in exactly the right place on the crush can. Reinstall that bolt, then do another, until all 4 are done.

You could do this but only on the outer facing bolt holes because you have to mount the winch to the tray then mount the tray/winch assembly between the frame horns. Cumbersome to say the least.
 
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ntsqd

Heretic Car Camper
The way around the crush thing is to drill only one side big enough for the anti-crush sleave to fit thru, and carefully cut the sleave's length to be flush on the big hole side while butted up against the inside of the small side. Then you can weld the big end to the outer face of the frame tube while a bolt centers the far end.
 

R_Lefebvre

Expedition Leader
Why not just go all the way through and weld both sides?

How about just redrilling all the holes and use larger fasteners? That would take up much of the slotting.
 

TJVach

Observer
Thanks everyone that replied! It looks like I might just eventually go with the bolt-on shackle or if I dare say dixon-bate idea. I think it would give me a little reassurance in that area. Thanks for your help all!
 

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