New bar for MK Patrol

[nz4x4]

Ok, Started to build a new bar to house the new Hi Mount. The main part of the bar is all welded up now. Just needs grinding down and fitting up (bolts for chassis and winch).

then I will start on the tube work for the sides and top.

I am by no means an expert welder but I think the welds are going to be plenty strong enough and look OK. Whats your opinion?
A bit anoying when you know that the welder is at its maximum capibility though. (240V, 180A at its highest settings running 0.8mm wire)

Once i get all ground down and the tube on it will be sent to the sandblasters so i have a nice clean surface to paint.

anyway, little chat, lots of pics......


Tacked up


Bottom tacked up


Inside tacked up


Me welding up the side


The side welded up


Side ground down. This is what i am going to do to all the exterior welds


Two front plates welded together


Me welding in the support tabs


Support tabs again


All welded up ready for grinding


Inside finished and ready for a clean up

[coxsy]

hi at 180 amps with mig the welds are a low hydrogen weld , and the mount will be more than strong enough

[doddzee]

Why have you gone for the high mount instead of the pto?

[nz4x4]

I couldnt find a way to get the PTO close enough to the body or high enough. Which resulted in a less then ideal approach angle.

I did try for a long time (talked to different people, looked at other designs etc) to find a way that would still alow the use of the PTO but also give me a very good approach angle.

The main problem with the PTO is the drive shaft and where it runs. I was unable to move the winch upwards because the driveshaft would have fowled on the chassis cross member and/or an engine mount. The amount of work to overcome this was to great and not worth the hassel.

The Hi mount came up at a good price (under $800) and allowed me to design a bar that would give the best possible approach angle. Its also very easy to replace a hi mount if it breaks. (doesnt seem to be a hell of a lot of spare PTOs around for the 3.3)

The plan is to run a 7.8HP motor on the Himount as well as some sort of extra cooling system in the future to get the best out of it.

[DieselBoy]

Bugger, i wish i had a photo.

A guy in the buller club had a MWB Cruiser with a PTO on it. He lifted the winch right up by leaving the PTO shaft where it was and running an external chain drive from the PTO shaft to the winch gear box. It was awesome, he rigged it up to futher reduce the gearing of the winch, which you can get away with on the Toyota PTO set up as you can use the gearbox to control the winch speed.

I must have a pic of his setup somewhere.

[nz4x4]

That would be interesting to see!

On a side note. The old PTO bar was mounted to the chassis with 2 bolts each side (4 total) not exactly sure what size they were but were around 14mm in diameter. I planned on using the same sized bolts (grade 8.8 ) so that i could use the 3 existing holes on each side.

so will 3 grade 8.8 bolts that are approx 14mm in diameter on each side be strong enough to support the bar and winch while winching?


Cant believe i cant exactly remeber what size bolts they are!!!



carrying on though.

I got it all ground up today. Looks good I think, just need to fill in a couple of marks in the side with the welder to make it nice and smooth. and then will sort my tubing out next week and then once it is all together it will go to be sandblasted.

Pics

All ground up



Close up of ground edge


Marking for winch mounting and fairlead holes

[nz4x4]

More progress. got the holes drilled and the fairlead slot cut and mounted the winch and tow hooks.
It goes it to be wired up on Wednesday next week.

Pics

[doddzee]

Looks good what are you planing on doing out the sides to protect your head lights?

[nz4x4]

Tube work, much like the GQ Ontrack bullbar. Eventually the external cage will mount up to the front bar.

[nz4x4]

Well i got the bar mocked up into place today. It actually sits about another 15mm towards the truck but you get the idea.