Lifting alloy bullbar After bodylift: Help needed

Well after my bodylift just been driving around with a big gap between the bullbar and the grill, looks ridiculous.

The only way I can see to fix it is:

1. Change the way the bar mounts to its brackets.
Probably the easiest to do only requires 1 extra hole per side but looks to be very weak and probably wouldn't stand up to a roo or similar.

2. Plate the mounts. Essentually extending the mounts up 50mm to be the same as factory. gonna be a PITA to do.

Gonna have to remove all the paint off mounts, grind off nuts (welded to mounts). Weld an extra 50mm of 6mm plate on top and also plate the inside of the mount for strength (plug welds). Grind smooth, cut new holes and weld on nuts again in new position(s). And repaint.

Would option 1 be strong enough??
Or do i just say f**k it and do it properly the 1st time and spend all day on it.

Do it properly first time. My bar is for a 2wd, so when I fit it to mine I had the same problem as you, and it took so long to do the hack job in anticipation of doing it properly that I may as well have just done it properly the first time.

I cut my mounts and rewelded them with an offset. They were so overspecified to begin with it didn't matter.

G day tommy, you installed zordo's body lift kit right ? i got the same one off him and am going 2 put it on this weekend. I personally would just do it right the first time, i know its going to be a pain in the f%#@ing ass but at the end of the days its your pride and joy and you want to keeps her looking good. also i know i wouldnt sleep right at night knowing that if a did happen to run into something or someone that my bull bar wouldnt hold up, let us know how you go and maybe a few pics would be great. Cheers

Matty

matty said:

G day tommy, you installed zordo's body lift kit right ?

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Yeah Matty, see the guide in DIY section

matty said:

i got the same one off him and am going 2 put it on this weekend. I personally would just do it right the first time, i know its going to be a pain in the f%#@ing ass but at the end of the days its your pride and joy and you want to keeps her looking good. also i know i wouldnt sleep right at night knowing that if a did happen to run into something or someone that my bull bar wouldnt hold up, let us know how you go and maybe a few pics would be great.

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mmm, will phone mrs welder and arrange a date...

How does it affect air bag operation (if at all?)

Does the OP have airbags? You can't do a bodylift on vehicles with airbags in some states. Can't remember which, either/both VIC or QLD.

Definately QLD, needs eng cert.

Airbag sensors are on the body not the chassis (from memory)

Bodylift doesn't (or that minor who cares) affect their opperation.

Ok, Finished this Today.

Took the easy option as its only an alloy bar and its as strong as after lifting it.

Here the bar before the lift (notice big gap ~ ugly)


Bar off (4x12mm bolts with captive nuts on mounting brackets)


Here's the bar to chassis mounting (s)

Drilled 1 hole each side in the bar first and fitted up to ute and marked the holes on the 12mm steel plate. (12mm is thick especially with a blunt 1/2" bit)
You also need to grind/file a 20x10mm section out of the bar to allow the mounting brackets to poke through. (horizontal plate belwo bullbar mounting tabs)



#Note: be careful when alligning the wings!

End result

looks good mate.......but just remember to leave a big enough gap so is when you do hit something it doesnt push your bar up and damage your body;ie your flares.just a thought,cheers.

Nice work mate.

That will hold as good as original I recon.

I did my Patrol alloy bar today as well. Also did a bit of customising on it as well.

Must have been the day for it.

Laith said:

Nice work mate.

That will hold as good as original I recon.

I did my Patrol alloy bar today as well. Also did a bit of customising on it as well.

Must have been the day for it.

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Yeah, had an impacted wisdom tooth out last week, so needed some thing to take my mind off the ache.

Also did my chrome rear step as well. Was only Drill 6 holes 2" lower down. (did this 1st, hense blunt drill bit)

tommy222220_0 said:

Was only Drill 6 holes 2" lower down. (did this 1st, hense blunt drill bit)

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Pilot holes and cutting oil?

Pro-Nav2.7TDi said:

Pilot holes and cutting oil?

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Yep, Centre punch, pilot then 3/8" then 1/2"
was to awkward to fit in the press. ::

I know its my own fault, but all hardware shops are closed when ever I start, so have to make do with what I've got.

tommy222220_0 said:

Yep, Centre punch, pilot then 3/8" then 1/2"
was to awkward to fit in the press. ::

I know its my own fault, but all hardware shops are closed when ever I start, so have to make do with what I've got.

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At least once it's already blunt you can go into it with the full body weight without worrying

Hey tommy, I just got my body lift in last nite... looking at the thickness of the bracket i can see why your drill bit went blunt!! any pointers? i can see it being tedious!

snowy85 said:

any pointers?

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Buy a new drill bit before your start and ask a mate over to help.

..and plently of liquid pain relief before, during and after.

tommy222220_0 said:

Buy a new drill bit before your start and ask a mate over to help.

..and plently of liquid pain relief before, during and after.

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Ahh mate the body lift was painfull enough!! 6 friggen bolts supplied were incorrect! im having a drama of a time tryin to find 2 more... ive managed to find ones for the other 4... but for the ones at the rear of the cab! NIGHTMARE!

Did you guys put that tailshaft safetly loop back on with some spacers or something or did you ditch it?

Cheers
Paul

snowy85 said:

Ahh mate the body lift was painfull enough!! 6 friggen bolts supplied were incorrect! im having a drama of a time tryin to find 2 more... ive managed to find ones for the other 4... but for the ones at the rear of the cab! NIGHTMARE!

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Who did you get the kit off? I got mine from Zordo on here and everything went together perfectly.

snowy85 said:

Did you guys put that tailshaft safetly loop back on with some spacers or something or did you ditch it?

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Put mine back on, as the long range tank goes over the tailshaft. Just used some 50x50x3 RHS as spacers.