Rear Bar Concept Images

[FlyingBushPig Advanced Member Find all posts View Profile Close FlyingBushPig]

Hi all, wasn't sure if this should be in accessories or modifications, anyway...

As you may know, my rear bumper is losing it's dodgy paint, has dents etc and really needs replacing. I figure it may as well be replaced with something tougher so I'm looking at creating my own custom job.
I haven't done a lot of this type of thing although I'm currently rebuilding a trailer to give me some practice.

I've come up with a concept of what I'd like. The little circles above the reflectors are superbright LED's for decent reversing lights, the other one on the left is a cover behind which will be an air line outlet.
The cuts are for jacking points - both up and for shifting the vehicle sideways..I like high lifts, let's not bring up that one here.

Questions are..
1: Is something like this doable, using welds rather than bending like ARB do? I realize the reflector holes would need laser cutting.
2: Should I put recovery points on here (would I use them) given I usually use the hitch type which replaces the tow hitch. If so, where and what type?
3: Any other suggestions of things I might have missed?
4: What colour?? It's a flareless GX and I don't have a bullbar yet - will probably get a Sahara bar.

This is a long term project so don't expect it done tomorrow - just getting some research started.

Original Bar...



And the Concept...

[foxclan Avid PP Poster! Find all posts View Profile Close foxclan]

Re: Rear Bar Concept Images

Love the concept drawings Phil, would sure give those car park volvo's a head ache and improve your departure angle.
Cheers Troy

[ozwapet2 Advanced Member Find all posts View Profile Close ozwapet2]

Re: Rear Bar Concept Images

looks beaut ...I'd have one tomorrow if they were on sale.

[OldGreyGuy Senior Member Find all posts View Profile Close OldGreyGuy]

Re: Rear Bar Concept Images

I think the bar has to come out a little to offer the bottom of the door some protection, if it is flush then a simple knock from a Volvo could simply ride up and trash the bottom of the door, a rear bar that projects say a couple of inches would offer some more protection. I could have just misread the image as well, just can't work out the depth from the image. Just my $0.02.

I like the fact that you are not trying to add on other wheel mounts and jerry can holders, etc., looks good.

[OldGreyGuy Senior Member Find all posts View Profile Close OldGreyGuy]

Re: Rear Bar Concept Images

I think the bar has to come out a little to offer the bottom of the door some protection, if it is flush then a simple knock from a Volvo could simply ride up and trash the bottom of the door, a rear bar that projects say a couple of inches would offer some more protection. I could have just misread the image as well, just can't work out the depth from the image.

I'm less tired this morning and can see better. Now I see in your diagram that you are basically imitating the standard bumper cover with steel and providing possibly a better angle of approach. I still like it.

Looking at the jacking cutouts you have, isn't there a rear chassis bar behind the current bumper? Would this be impacted?

Would love to see your designs taken a little further.

[FlyingBushPig Advanced Member Find all posts View Profile Close FlyingBushPig]

Re: Rear Bar Concept Images

Yes, I've tried to replicate the styling and general look of the Prado bar but taken some of the lines (departure angles etc) of the Sahara bar.
What you say about the chassis is quite possibly correct and I'm sure there'll be all sorts of things to deal with behind there. I just wanted to create a starting point with the look and go from there.
I'll try to do some more work on the designs (side angle etc) and have a bit of a look behind there to see what might be a problem.
I think I'm happy with the look though.

[MUMSRIG Avid PP Poster! Find all posts View Profile Close MUMSRIG]

Re: Rear Bar Concept Images

WOW Phil, that will look sensational once completed.

I'll be watching this thread....

Mitch

[8608 Advanced Member Find all posts View Profile Close 8608]

Re: Rear Bar Concept Images

i've been thinking about this also since i first bought my prado.

concept drawings are easy. trying to make it isn't.

somethings i found through some basic reasearch of existing rear bars on the market are.

very hard to incorporate the side bits of the bumper. (reflectors to wheel arch)
most manufacturers are cutting these sections and using the original bumper to fill in the space.

if you were to incorporate the sides for 100% protection, you will be adding massive weight ontot he bar and the rear of the prado.

i would not use the toyota hitch/tow bar if you are making one from scratch. i would remove it, design the rear bar to incorporate a hitch receiver and bolt/mount the centre section of the bar to the chassis much like ARB's towbar. (i can take a pic of the ARB tow bar for you)

try and have a look at a KAYMAR rear bar in the flesh if you can. if i had the money, i would just buy this bar even with out the wheel carriers. I think you can even order the KAYMAR bar with No RWC pivots. this also has a towbar incorporated into the bar and not a seperate one.

trying to cut large pieces and welding them all together may be a challenge. you will need to brace the inside heavily if your steel is not thick enough.

weight is my major concern.

but by all means, give it a shot and let us know how it goes. i will be watching this thread with interest.

cheers

[FlyingBushPig Advanced Member Find all posts View Profile Close FlyingBushPig]

Re: Rear Bar Concept Images

Thanks guys, sorry, I hadn't realized there were replies to the thread!

8608...your thoughts are the same issues I see coming up..however there's a few reasons I'd like to pursue this somehow:

Kaymar's stuff is great - their factory (& ARB's factory) are just down the road so I can easily have a look at them BUT..their bar will not suit a GX without the flares. As you say, the bar meets the flared section behind the rear wheel arch and will look odd with the GX - I checked with Kaymar at the ARB open day last year. Also, they're VERY expensive.

Do you know why they do this? Why don't they extend the bar right through? Is it due to not having a strong place to mount the bar at that point? The reason I don't want to use these pieces is that mine have the terrible paint peeling problem and have some small dents from being off road - which tells me that's where I DO need protection.
As you say, the weight issue is a big one. If it's well designed, hopefully I can do something to keep this down.

The 100 series ARB wheel carrier DOES extend right through out of interest - I need to desperately take the whole bumper off and do some real thinking soon.

Not going to start on this project for a while yet (fixing a trailer up first). Just want to work on it slowly over time so when I'm ready I can get it right.

Any more ideas would be great. It seems the hi lift points will need to be moved after a quick look but no biggy.

[germar74 Lurker Find all posts View Profile Close germar74]

Re: Rear Bar Concept Images

Phil
I think your design is fantastic ... I was just looking at some pictures of the Kaymar bar and your design is the prettier of the 2 fitting with the niceties of the prado already
do you have any thoughts on how the sides might look? I wonder what it would cost for a fabricator to build one of these
Cheers Gerard

would you mind if I sent your pic through to 2D Extreme - http://www.2dextremefabrications.com.au ... type=large
to find out a build price ... please do say no if you do not want me too
cheers gerard

[ModdiFyd Lurker Find all posts View Profile Close ModdiFyd]

Re: Rear Bar Concept Images

Hi all, wasn't sure if this should be in accessories or modifications, anyway...

As you may know, my rear bumper is losing it's dodgy paint, has dents etc and really needs replacing. I figure it may as well be replaced with something tougher so I'm looking at creating my own custom job.
I haven't done a lot of this type of thing although I'm currently rebuilding a trailer to give me some practice.

I've come up with a concept of what I'd like. The little circles above the reflectors are superbright LED's for decent reversing lights, the other one on the left is a cover behind which will be an air line outlet.
The cuts are for jacking points - both up and for shifting the vehicle sideways..I like high lifts, let's not bring up that one here.

Questions are..
1: Is something like this doable, using welds rather than bending like ARB do? I realize the reflector holes would need laser cutting.
Everything is do-able, it just depends on how much time and patience you have, welding should be fine as long as your cuts line up niceley with not too much of a gap, dont know what you are using to weld with but would seriously consider using the MIG for this. could make a prototype out of cardboard first, pull apart to get individual shapes then tack everything together and do a trial fit before fully welding.
2: Should I put recovery points on here (would I use them) given I usually use the hitch type which replaces the tow hitch. If so, where and what type?
I personally would stick with the hitch3: Any other suggestions of things I might have missed?
Could use a holesaw, nice and slow, plenty of cutting fluid for the LED recesses
4: What colour?? It's a flareless GX and I don't have a bullbar yet - will probably get a Sahara bar.
Personnaly would colour code, but thats just me
This is a long term project so don't expect it done tomorrow - just getting some research started.

Bar looks very interesting would love to see the finished product, take your time it looks like it will be worth the effort.[/

Original Bar


And the Concept...

[germar74 Lurker Find all posts View Profile Close germar74]

Re: Rear Bar Concept Images

Just letting everyone know
I have sent (with FlyingBushPig's permission) the pic of this concept bar to a local guy in brisbane to see if he can build them. He makes great side steps at $595 a set, will let everyone know details after I have had mine built (3 week wait at the moment, booking mine in ASAP - purely self centred decision :twisted: ) but for under $600 a set it makes a good starting price to send around the country.
Cheers Gerard

[Just*Managing Member Find all posts View Profile Close Just*Managing]

Re: Rear Bar Concept Images

It looks great. Will be very interesting to see if it can be done for that sort of price

[ntp Addicted PP Member Find all posts View Profile Close ntp]

Re: Rear Bar Concept Images

Be interested to know what its likely (extra) weight will be.

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Re: Rear Bar Concept Images

If you just want a rear bar, and it does not need to support spare wheels, etc then why not make it out of ally?

I know I have a habit of pushing over scrub when reversing and I've got a whole swag of scratches and little chips out of the plastic bar. I'd be happy with something that just offers enough protection without weighing half a tonne. I already have recovery points on the rear hitch so don't need to incorporate jacking points of the rear bar.