GU rear Half bars / quarter chop

[rb30e]

Hi Guys,

got sick of the crap plastic rear bars on my series 1 GU wagon always coming off and having to cable tie them back on. Plus the rear lights always falling out, put that many dodgy tech screws in them to hold them in it was looking hideous.

I decided to make some half bars and chuck the old ones, plus help increase my departure angle to a degree.

Pics below

[threedogs]

Rear bar if you'd call it that are usless. was toying with the idea of making sheet metal ones with increased departure angle, and still look factory. look forward to pics of what you come up with

[rb30e]

I didn't take a whole lot of pics to begin with but this is the bare frame of it.

You can see I used a section of the old reinforcing that sits behind the old plastic rear bar.

I cut it in line with the chassis rail and welded a 4mm plate to cap it off. I the drilled two large 14mm? holes for the bolts to fasten it onto the chassis rail.

using my mandrel bender i bent up some sections of 1 3/4" mild steel tube. was my first project with the pipe bender and took some serious stuffing around to figure it out and get all the bends right.

To secure the front half I welded a straight it of pipe towards the chassis rail accessible through the wheel arch. Then welded some mounts onto the chassis rail to make it easy to remove if necessary.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0707.jpg

[rb30e]

Three dogs, Rear bar if you'd call it that are usless. I found the stock ones useless as mentioned I tore them off that many times and the lights especially. Had to find something more permanent, which could also help with the departure angle as a secondary objective. I guess it depends on how serious you want to go 4x4ing and the kind of situations you may find your car in

The center section of the rear bar is fine for me so I figured why change it, I only wanted to make something up for the crap corners that fall off all the time. And fix up the rear lights

[rb30e]

my mandrel bender in action.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0640.jpg

[rb30e]

the two finished products now in primer

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0716.jpg

[rb30e]

wanted to fit it to the car and figure out how much of the rear quarter protrudes so i could mark it out ready to cut the bastard off.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0715.jpg

You can also see the ebay fully functional lights I've already installed and wired up. not bad for $120.

[rb30e]

now to mark off the section of the rear quarter thats gotta go.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0723.jpg

http://http://i498.photobucket.com/albums/rr348/shitavl/IMG_0724.jpg

[threedogs]

Looking good, plus if you get whacked in carpark now they'll come off second best, those benders are worth every penny, awesome piece of kit for the workshop. didn't want to fill in with checker plate and recess some LED lights?

[rb30e]

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0724.jpg

[threedogs]

What area you from???

[threedogs]

After you cut rear how are you finishing it or just leaving straight?

[rb30e]

Threedogs, didn't want to fill in with checker plate and recess some LED lights?

was thinking that but bloody hell this was enough work as it is, plus they were bloody heavy enough already.

Oh yeah and those pipe benders rock, halfway through making up some brush bars and got a roll cage planned for my 383ci Volvo haha

[rb30e]

Quarters gone, took some mucking around to get that off with my pissy 115mm grinder.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0726.jpg

[threedogs]

You know dummy lights are illegal don't you, they are for overseas models with no wheel on door, hope this doesn't bust ya bubble. Can get slimline LED to suit I would think

[rb30e]

Cleaned up the inside sections so I could fit a plate inside rather than over to make welding it one easier.

Not the cleanest cut but the mig fixes the gaps

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0728.jpg

[threedogs]

Looks like a lot of work but those FLAP DISC are heaven sent for finishing steel, lots of cutting, bending and checking for sure Mate

[rb30e]

Marked out the section by covering it with a bit of paper, which I marked, cut out and used as a template. Then used my newly purchased plasma cutter to cut out the plate. Plasma cutters rock!!!

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0731.jpg

[rb30e]

Threedogs,
Looks like a lot of work but those FLAP DISC are heaven sent for finishing steel, lots of cutting, bending and checking for sure Mate

Yeah the flap discs sure got a work out, your not wrong all the bending, cutting, welding, grinding and painting. Fark me a lot more work than I was expecting. bet the neighbors love me now. I was almost thinking all the time I put into this woulda been better off buying something. It was my first fabrication project though and I was learning how to use all mu new fancy tools, nothing quite like being able to make something up yourself and getting a decent result.

[rb30e]

Plate welded in place. I'm an amateur welder at best and this was my first real project. I only had 4mm plate to work with. tell you what, welding 4mm plate to 1mm body panels upside down is a fair challenge.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0733.jpg

[rb30e]

I then marked off the remaining section and painted it black, to blend it in with the bar.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0742.jpg

[rb30e]

And finally the finished product, thank god what a lot of work, not to bad for my first fabrication product me thinks!!!

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0745.jpg

[rb30e]

gotta do something about that exhaust though, its hanging out like a dick in a shirt sleeve

[threedogs]

X2 I'm similar to you, now you have a one off rear bar that no doubt someone in the bush will ask you where you brought it, how proud would that make you. Job well done look forward to seeing it painted all finished. Got some great TOYS out there for the workshop for sure, Next you'll have to do rock sliders, bullbar Hey when do you stop. sliders would be handy though

[rb30e]

This the section where it mounts to the chassis on the front for extra strength. had to make sure it would not foul where the wheel travels.

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0753.jpg

[threedogs]

As with all weldind get comfortable, get your amps right and take your time, nothing better than a good looking weld. my mate can't weld so he welds grind welds grind welds grind. He gets it till I go over LMFAO at some of his attempts, good to see you used zinc bolts did you use rated ones?

[threedogs]

Exhaust shop should be able to bend up a tail pipe for you, sice dump would look good. What next RB30e MOD SHOP + fabrication

[rb30e]

One more shot for good measure, me in my wheelchair grinding the welds clean in my shed. Certainly adds to the challenge doing it all from a wheelchair, set my legs on fire twice while welding and using the plasma cutter and didn't even know until I stopped welding and smelt the smoke, ruined two pairs of work pants haha

http://i498.photobucket.com/albums/rr348/shitavl/IMG_0680.jpg

[rb30e]

As with all weldind get comfortable, get your amps right and take your time, nothing better than a good looking weld. my mate can't weld so he welds grind welds grind welds grind. He gets it till I go over LMFAO at some of his attempts, good to see you used zinc bolts did you use rated ones?

Yeah funny you say that when i started my welds were pretty crap my GIRLFRIEND came round and taught me how to weld better, being a blacksmith and fabricating horse floats she certainly knows how to weld better than me.

The bolts are high tensile, could only use 8mm bolts with the size of the flange but should do the trick, wonder if i could get the high lift onto it, probably better not unless left with no other option.

[threedogs]

Nothing worse than a spark down the front of your pants when you cant let go. just gotta let it burns and hope the twins are ok LOL. No, really good job, just wait everyone will comment and want a set. Better start thinking of a RRP$$$. I have Anvil and Blower as well, just make rustic stuff for mates, and Fab most mods on truck to make it Different. Check my rear wheel on vendor thread,

[CUROUND]

Well done rb30e. Great post and impressive work. Even jealous of ya clean shed. My sheds bigger with lots more junk, and I hardly get in there. Well done. I enjoyed the post.
Cheers :clapping::thumbup:

[megatexture]

nice one mate, looks great. i just wish i had the tools to do this stuff ohh and the know how haha