unless they have changed thier range recently but the arb bar on my d40 d/c work ute is identical to the nissan bar and it moves up and down about an inch and squeaks quite badly and this is suppose to be the chassis mounts ive been a mechanic for ten years and worked for nissan for four of those and have never seen this optical illusion
Not going to get into a p!ssing content with you mate. I'm a qualified mechanic too - started my trade about 25 years ago - nice to see other spanners on the site.
I'm merely stating what I have seen and what I have experienced.
Since completing my trade, I have owned quite a number of 4wd vehicles - most of them body on frame designs. And those body on frame designs use soft mounts to mount the body to the frame. Yet when mounting a bullbar, use rigid mounts to mount the bullbar to the frame. The optical illusion comes from the natural movement differential that happens when the relatively stiff bullbar doesn't move, and the relatively soft body does move.
If the bullbar does move so much, riddle me this.....travelling up a corrugated road at night. The bullbar appears to "shimmy" in comparison to the front guards. But the driving lights (mounted to the bullbar) don't budge... If the bullbar was moving around, then the lights would be flickering all over the place, yet they don't.
The design of the ARB bar has never changed. They have changed they indicators and foglights, but nothing else. The steel nissan bar for the d40 has not changed in it's look since release.
The Nissan bar has a centre loop, the ARB bar does not. The ARB bar has one continuous loop of tube that runs from one side of the bar to the other. (Actually, depending on the bar, it is either one continuous piece, or several pieces of steel - but you probably already knew that didn't you.) The Nissan bar has a "lowered" centre section in the middle of the bumper area. The ARB bar does not. The Nissan bar uses small rectangular black plastic surrounds around the indicator/parking lights that ARB have never used on the D40 bar. Indeed, I don't recall ARB using that design on any bar design... Anyway, whether you agree or not - the bars are not the same. End of lesson.
Sounds to me like there could be quite a simple explanation for the movement - the mounts need some work. There are shims that are supposed to be installed in the ARB bar mounts - not sure about the Nissan bar mounts - and if these are missing, then it could explain the movement you are talking about. Similarly, if any of the mounts are loose, then it could explain the movement. But then not having seen it myself, not having checked any of that, I don't know myself. There are a LOT of bolts on the ARB mounts - from memory, something like 8 or 10 each side??? That is just to mount the "mount" to the chassis rail. Then you install the bar to the "mount" with another (from memory) 3 big bolts each side, align the bar carefully, then you need to carefully drill 4 "pinning" holes. Once pinned in place, there is no static movement between the bar and the mounts. None. Zero. Which is why I raised the point about the mounts perhaps being the problem.
All I do know is, that on my D40, with an ARB deluxe bar installed (myself) according to specification, there is no static movement - yes, a small amount when underway as I would expect with the frame and body on soft mount design of the D40. Same as the rodeo I once owned, same as the patrol I owned, same as the wrangler....the list goes on.
As for price of deluxe bars - shop around. I was offered one for a shade over $1300 (black powdercoat) from the sydney ARB place near the airport. One of the big problems with colour coding at the moment is that ARB have approx a 3 week backlog in their paint shop...
With regard to the Sahara bars - this is hearsay so happy to be corrected. I believe the centre loop is bolted in place, not welded. If this is true, the bar would be of limited protection value. Good for winch mounting, but the bolt-on centre loop is nowhere near as strong as a welded section. And there is no real protection for wings obviously, but that might be not what you need. Obviously everyone has different needs.