[swifty_ano]

Ok so im a fabricating retard. I'm a great designer, but when it comes to "Brain to Hands" I am hopeless.
However, I really really want to learn and DIY alot of my bar work.
Not just because i'm a tight ass but because I want to be the guy on a 4wd Action dvd that says "a rear bar I made" and not a "thanks to the boys at so & so fabrication"

Enough jibba jabba......

basically I want this rear bar:


However, I don't know where to start.
Because I don't have acess to a bender, I was planning on grinding the back of where the bends need to be, bending it and weld along the bend. Is this possible?

What are your thoughts on how to get those raised parts underneath the tail lights?





Any input woul be fantastic

[want33s]

There isn't much holding a Vit rear bar on stock.
Are you going to mount the new (big heavy) bar to the body or direct to the chassis?

[swifty_ano]

to the chassis Jason. Why's that? what do you think is best?

[suzukiboy]

I used U channel for the main bar, cut a couple of V's to bend the bar, (because it is not flat across the back)and steel shelving for the ends and mounted to the original points.

Lights are the original fogs.

[DarkHorse]

Def chassis, I think that's what Jase was hinting at.

There's 4 big chunky threaded holes at the ends of the chassis (M16 maybe, can't remember) where tow-bars bolt on. That'd be a good start, and use the three mounting points on the top of the stock rear bar (under the plastic skin) as your main foundation, then the various other little points the stock bumper bolts/screws in can either be upsized or just used as place holders.

[swifty_ano]

suzukiboy wrote:

I used U channel for the main bar, cut a couple of V's to bend the bar, (because it is not flat across the back)and steel shelving for the ends and mounted to the original points.

Lights are the original fogs.

Mate could I bother you for a more in depth explanation on the "cut v's".
Also, why did you mean by steel shelving ?
How did you do the raised bits under the tail lights?

[suzukiboy]

swifty_ano wrote:

suzukiboy wrote:

I used U channel for the main bar, cut a couple of V's to bend the bar, (because it is not flat across the back)and steel shelving for the ends and mounted to the original points.

Lights are the original fogs.

Mate could I bother you for a more in depth explanation on the "cut v's".
Also, why did you mean by steel shelving ?
How did you do the raised bits under the tail lights?

With the V cut, I cut a V section out of the top edge of the U channel so I coul bend in each side the V cut meets up and then you can weld it up.

Steel shelving I had lying around was great because it was pre bend on the edge to add strength to the bar.

Raised bits were just falt pieces welded in place.

Will take some pics won't be untill the weekend Vitara is stored at my mates, driving my new Sierra around.

[JrZook]

suzukiboy wrote:

driving my new Sierra around.

Bout time for pics Dave

[Fatzook]

DarkHorse wrote:

There's 4 big chunky threaded holes at the ends of the chassis (M16 maybe, can't remember) where tow-bars bolt on.

M12 fine.

The only place you will find an M16 thread on a suzuki is the Tie rod ends

[swifty_ano]

suzukiboy wrote:

swifty_ano wrote:

suzukiboy wrote:

I used U channel for the main bar, cut a couple of V's to bend the bar, (because it is not flat across the back)and steel shelving for the ends and mounted to the original points.

Lights are the original fogs.

Mate could I bother you for a more in depth explanation on the "cut v's".
Also, why did you mean by steel shelving ?
How did you do the raised bits under the tail lights?

With the V cut, I cut a V section out of the top edge of the U channel so I coul bend in each side the V cut meets up and then you can weld it up.

Steel shelving I had lying around was great because it was pre bend on the edge to add strength to the bar.

Raised bits were just falt pieces welded in place.

Will take some pics won't be untill the weekend Vitara is stored at my mates, driving my new Sierra around.

Mate I appreciate the help. What size U channel? Thickness?

[DarkHorse]

Fatzook wrote:

DarkHorse wrote:

There's 4 big chunky threaded holes at the ends of the chassis (M16 maybe, can't remember) where tow-bars bolt on.

M12 fine.

The only place you will find an M16 thread on a suzuki is the Tie rod ends

Thought they were bigger than that, but I'll take your word for it

[want33s]

swifty_ano wrote:

to the chassis Jason. Why's that? what do you think is best?

Mounted to the chassis is the way to go.
A rear bar isn't the easiest job for a beginner, you might want to try a few smaller jobs first to get the hang of it.
EG: Bashguard or 2nd battery tray or something.

Something else to think about is the clearance between the bar and the body.
If the bar is chassis mounted there WILL be movement so it won't want to be too tight on the body.

[suzukiboy]

Here are a few extra pics.

[oohsam]

Hey mate,
I'm actually in the process of using the design of this rear bar to make my own like this.
I am doing it a little different though.

It will be made from steel, but each flat section will be a piece of steel, and welded together, then cleaned up and powder coated. I will not be doing the cutting, the auto-cad will be sent off to be pre-cut, and I'll just weld it together and fit it.
I just dont have the available tools to do the cutting, and i want the cuts to be very clean. I also dont have acces to a folder anymore, but I'm considering buying one!

Will be bolted directly to the chasis.