surf rear protection bar.......Build time!!! :D

gomulletgo · Post by **gomulletgo** » Thu Feb 22, 2007 8:33 pm

The time has come to make a rear protection bar for my truck

bumper:

http://i95.photobucket.com/albums/l140/ ... 7_1044.jpg
http://i95.photobucket.com/albums/l140/ ... 7_1045.jpg
http://i95.photobucket.com/albums/l140/ ... 7_1041.jpg

exhaust crimp:

http://i95.photobucket.com/albums/l140/ ... 7_1056.jpg

I basically want to know if people think I should go for one big diameter piece of tube or two smaller ones? What have you done? I know I could make it out of something other than tube but I want to get a bit of practice bending and welding tube.

I'm not making a space shuttle so this will be done with a cheap bender and whatever welder I have access to at the time. Oh and it will be cheap tube aswell.....and I don't care if I end up with "crush bends" as long as it is strong enough to save my tailgate then I don't give a big rats ar$e...... Ha-haaa! take that you DOM, Tig, chromoly, Protools junkies :twisted:

If you have a tube bumper please take pics and post them up to give me ideas

Smurf · Post by **Smurf** » Thu Feb 22, 2007 9:25 pm

my surf came with a square box rear bumper, I took it off remounted it to make it suitable to tow off then added side bars.

For the bends I went to the local scrap yard, picked up an old front bullbar for 20 bucks and cut it up

Jafa · Post by **Jafa** » Fri Feb 23, 2007 4:09 pm

You can have this one for free if you want it

You can just see the end of it in this pic pokin out under the tailgate

It works well and is up high so dosn't get caught up, made outta 6mm steel and bolts directly in the end of the rails with bigassed m16 bolts

rokhound · Post by **rokhound** » Fri Feb 23, 2007 6:46 pm

To keep a tight line around the rear end pan you will find that using weld bends will work better, but I reckon the single 3" bar is the go.

I made my bar up after I had already dinged the back 1/4 panel.

Hadn't broken any lenses until this attempt though

A rear bar would be the first thing in the bar department when building another rig though.

wjw · Post by **wjw** » Fri Feb 23, 2007 7:05 pm

I'm panning on cutting the rear panels a bit and doing a bar like rokhounds

SupraLux · Post by **SupraLux** » Fri Feb 23, 2007 7:32 pm

Jafa's freebie would be a good start, but it won't fit the rear of a surf as the tailgate sits below the level of the chassis rails, even with a body lift...

I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong and somewhere I have the pattern for the plates you need to make to mount it...

If Conan reads this he'll hopefully post pics of his that I made with a built-in receiver hitch...

Steve

adventures_more · Post by **adventures_more** » Fri Feb 23, 2007 9:09 pm

Know of any exhaust/engineer shops that have a mandrel bender that can do 3" + in christchurch , NZ ?

Jafa · Post by **Jafa** » Sat Feb 24, 2007 1:19 pm

Ahh yes Steve, the rear of a Surf is quite different than a Hilux, tailgate is a lot lower, oh well never mind
I reakon that bar that Rok has is a sweet setup

kiwipete · Post by **kiwipete** » Sat Feb 24, 2007 7:21 pm

Keep these ideas and suggestions comming guys as I will be into this on my Terrano in a couple of months too as can be seen in the link below.

http://www.offroadexpress.co.nz/modules.php?set_albumName=Terrano-Modifications&op=modload&name=Gallery&file=index&include=view_album.php

Sorry for the hijack.

gomulletgo · Post by **gomulletgo** » Tue Feb 27, 2007 1:21 am

Thanks for the offer Jafa. But as steve mentioned getting it to fit would be too much work.

Rok that is certainly a nice bar and that is what I was intending on doing......minus the bits up above the main tube.....I would like to bend it myself if I can.....but I realise you can get a much tighter radius with weld-in-bends

I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong

That's the plan at this stage......wall thickness? 3mm?

I want to have the tube bar mount up using the existing towbar holes.....I also want to copy the towbar setup and make an entirely new towbar setup that is integrated into the tube bar....... dunno if that makes sense......what I'm trying to say is that I want to make a one piece tube bumper bar and towbar that bolt onto the surf chassis.

I kinda want to make my bar not so "tucked in" as your's rok....so it sits out far enough that it would be the first thing to hit anything that I was to back into by at least an inch.

Know of any exhaust/engineer shops that have a mandrel bender that can do 3" + in christchurch , NZ ?

I don't personally, but don't doubt that there are plenty....I am unsure whether you asked that question for my benefit or because you want to know personally.

maybe someone else can tell him where to find one?

Thanks for all the help and pics so far people

Much appreciated.....I hope to return the favour with pics of my own down the track

MATT4U · Post by **MATT4U** » Tue Feb 27, 2007 11:42 am

Something like this???

I may be looking at parting with it if your interested

SupraLux · Post by **SupraLux** » Tue Feb 27, 2007 12:46 pm

Thats so low and bent out-of-shape that I'd imagine if you really wanted to part with it you'd only need to drop off a bank somewhere

MATT4U wrote:Something like this???

I may be looking at parting with it if your interested

MATT4U · Post by **MATT4U** » Tue Feb 27, 2007 12:50 pm

its only low on my truck cause I have a body lift, its strong as, ITs survived my abuse for over a year.

gomulletgo · Post by **gomulletgo** » Mon Mar 05, 2007 2:26 pm

Something like this???

I may be looking at parting with it if your interested

Thanks for the offer matt

but I've already bought alooot of steel.....so I'm obligated and I really want to get some practice with making this sort of stuff under my belt.

(got big plans down the track :twisted:

)just out of curiousity why are you getting rid of it? have you made a new one? If so some pics of that would be kicka$$

MATT4U · Post by **MATT4U** » Mon Mar 05, 2007 4:08 pm

Im building a low profile one, .......

rollypolly · Post by **rollypolly** » Mon Mar 05, 2007 4:51 pm

SupraLux wrote: I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong

Steve

Where do you gaet your syeam pipe from, is that 60id or od? by the way is it api steam pipe????????????????? :wink:

rollypolly · Post by **rollypolly** » Mon Mar 05, 2007 4:52 pm

rollypolly wrote:
SupraLux wrote: I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong

Steve

Where do you get your steam pipe from, is that 60 id or od? by the way is it api steam pipe?????????????????

SupraLux · Post by **SupraLux** » Wed Mar 07, 2007 11:57 am

rollypolly wrote:
SupraLux wrote: I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong

Steve

Where do you gaet your syeam pipe from, is that 60id or od? by the way is it api steam pipe?????????????????

Don't overcomplicate the issue, just get some heavy-walled pipe and use the former that fits it

Steve

SupraLux · Post by **SupraLux** » Wed Mar 07, 2007 12:01 pm

Found some pics of the buildup of Conans rear bar... This might help. The dropped part of the side-plates is there to allow a hook to be mounted as well.

Steve

rollypolly · Post by **rollypolly** » Wed Mar 07, 2007 4:44 pm

SupraLux wrote:
rollypolly wrote:
SupraLux wrote: I'd go 60mm steam pipe, single tube. The thickness allows it to crush-bend well enough, its nice and strong

Steve

Where do you gaet your syeam pipe from, is that 60id or od? by the way is it api steam pipe?????????????????

Don't overcomplicate the issue, just get some heavy-walled pipe and use the former that fits it

Steve

i sell pipe!!! api pipe, steam pipe, galv pipe, weld bends :wink:

my real name is tark i work at taylors 360 tuam st if anyone needs some pipe or weld bends etc and i am in a good mood at the time, i can do good $$ on it, but let me know that u read it here on ore.

have a good day :lol:

p.s anyone want to weld me up sume rock sliders?

niblik · Post by **niblik** » Wed Mar 07, 2007 7:52 pm

rollypolly wrote: i work at taylors 360 tuam st

thats where i'm probably gonna go to get my pipe, from now on.. some dude looked after me.. sorry, names slips my mind at the moment.. :oops:

top fellow..

had a bit of a nosey round when i was gettin some tube.. lots of goodies in there..

dazza85 · Post by **dazza85** » Wed Mar 07, 2007 8:23 pm

Hey niblik
That looks great ... I might have to do the same for my surf
Did you make a pattern of the plates that go into the chassis?
Whats the idea of the plate across the bottom with the pair of holes near each end ??
Are you planing to keep using under body location for your spare ?If so how do you access the winch?
Keep postin' the pics

H2OLOVA · Post by **H2OLOVA** » Thu Mar 08, 2007 9:03 am

rollypolly wrote:p.s anyone want to weld me up sume rock sliders?

i can weld!!! could do a deal on some pipe if your keen...........

SupraLux · Post by **SupraLux** » Thu Mar 08, 2007 10:54 am

dazza85 wrote:Hey niblik
That looks great ... I might have to do the same for my surf
Did you make a pattern of the plates that go into the chassis?
Whats the idea of the plate across the bottom with the pair of holes near each end ??
Are you planing to keep using under body location for your spare ?If so how do you access the winch?
Keep postin' the pics

Thats not Nibby's, its mine

The bar with the holes was just some scrap I had that fitted... the holes don't do anything... I put that on for strength around the receiver socket (the rear bar is cut where the socket is mounted). The spare still fitted from memory, the truck belongs to Conan - I'm sure he can post pics if he still has it on - last time I heard he was shortening the truck up so he may have modified it.
Yes, I have a pattern somewhere of the side plates - I'll look for it in the weekend... its 5mm plate, and the strengthening is 8x30 or 8x40 flat bar from memory.

As for the pipe, it was a length I had from ages ago, I have no idea of the specs but it was heavy walled and weighed s%$tloads so I figured it would do the job

Tark, can you post a few specs of what you'd recommend for something like this? I only said use whatever looks strong enough because thats generally what I've done (only I normally look for something strong enough, then double it - nothing like a little over-engineering

)

Steve

monaro427 · Post by **monaro427** » Thu Mar 08, 2007 5:18 pm

hey steve if you find those patterns for the side plates on the rear bar i would be interested in getting a pattern of you if that is alright,

dazza85 · Post by **dazza85** » Thu Mar 08, 2007 6:16 pm

Hi Steve,
Sorry 'bout that :oops:

Thanks for the info

rollypolly · Post by **rollypolly** » Fri Mar 09, 2007 12:31 pm

i think that:

50mm nb x 3.6wall would be ok 6.5meter leights wight is 34kg @ about $75+gst(condensate pipe)

or

50nb x4.7wall would be better also 6.5meter leights wight 41kg @ about $150+gst (steam pipe)

or if you want to drive throw brick walls ect.

50mm sch80 api pipe(seamlees pipe) 6meter leights wall is 8.7.
about 44kg per leight @ about 210.00+gst
its a bit of un over kill

this is just a raff idea, hope it helps