Xrox Front Bar, Modified.

[Bilbo]

Hi guys, Here is another project I've just started. Not sure if it's been done before, couldn't find any info here. If it has I'd love to see some pics.

I'm spacing the wing on my Xrox out by 60mm and adding a rolled bar around my wheel arch to my sliders.

Obviously still in the early stages. The wing and rolled section will be one piece, then clamp on to the slider so that I can still remove either.

Any suggestions, hints or tips would be great.

Cheers Brett.

[macca002]

Looking good.

The amount of body movement the Triton gets put me off doing a similar mod - I was strongly considering it when I was putting together my side steps.

I am interested to see how this goes, might look into it again if you find there is no rub on the bars due to body flex.

[NowForThe5th]

Now that.......is neat.

[Bilbo]

Looking good.

The amount of body movement the Triton gets put me off doing a similar mod - I was strongly considering it when I was putting together my side steps.

I am interested to see how this goes, might look into it again if you find there is no rub on the bars due to body flex.

I'll have about a 12mm gap between the guard and the bar. Hopefully the body won't flex that much. Worst thing that can happen is it touch the flare.

[Bilbo]

Looking good.

The amount of body movement the Triton gets put me off doing a similar mod - I was strongly considering it when I was putting together my side steps.

I am interested to see how this goes, might look into it again if you find there is no rub on the bars due to body flex.

I'll have about a 12mm gap between the guard and the bar. Hopefully the body won't flex that much. Worst thing that can happen is it touch the flare.

[Juggz]

Solid. I do like it

[macca002]

Might be worth looking at how you can strengthen the xrox wings to take a side impact. Leaning up against the 'scrub bars' would put a bit of weight on the xrox wings, in a way they were not intended.

Without jumping under my 4x4 and taking a look, is it possible to run a brace from the outside corner of the xrox wing back to the cradle? That would strengthen it up a heap.

[4wd26]

yeah- but the wings are removable/ replacable

if they bend replace- not sure of the price, but better the wings bend than making too strong and the lean against something bends the mounts for the bar/ chassis

[salt36]

Looking good.

The amount of body movement the Triton gets put me off doing a similar mod - I was strongly considering it when I was putting together my side steps.

I am interested to see how this goes, might look into it again if you find there is no rub on the bars due to body flex.

I'll have about a 12mm gap between the guard and the bar. Hopefully the body won't flex that much. Worst thing that can happen is it touch the flare.

Nice work Bill, will look sweet when finished

I have about 6mm between my scrub bars and my flare, been on for about two years I think ( would have to check my build thread)
Anyway no marks from the bars touching the flares anywhere. Have done some decent off road flexing, wheels in air etc too.

[macca002]

yeah- but the wings are removable/ replacable

if they bend replace- not sure of the price, but better the wings bend than making too strong and the lean against something bends the mounts for the bar/ chassis

If you were to weld to the cradle, it is before the crumple zone of the bullbar (the wavy bit of the bar/brackets) so shouldn't have any issues with chassis bending.

[Bilbo]

Looking good.

The amount of body movement the Triton gets put me off doing a similar mod - I was strongly considering it when I was putting together my side steps.

I am interested to see how this goes, might look into it again if you find there is no rub on the bars due to body flex.

I'll have about a 12mm gap between the guard and the bar. Hopefully the body won't flex that much. Worst thing that can happen is it touch the flare.

Nice work Bill, will look sweet when finished

I have about 6mm between my scrub bars and my flare, been on for about two years I think ( would have to check my build thread)
Anyway no marks from the bars touching the flares anywhere. Have done some decent off road flexing, wheels in air etc too.

Thanks for this info, so 12mm gap should be ok.

[brodical]

Where did ya get that tube bent too suit ....looks quite neat mate....I like it....would be good rather than the butt weld onto the xrox but a continuation from the top xrox tube if you catch my drift ....would give it a sleek look....

[Bilbo]

Where did ya get that tube bent too suit ....looks quite neat mate....I like it....would be good rather than the butt weld onto the xrox but a continuation from the top xrox tube if you catch my drift ....would give it a sleek look....

Yep I know what you mean, and I agree. I had the steel rolled in Lonsdale. I couldn't find any mandrel bends, pre bent or anyone capable of bending a tight enough bend to suit the transition from the top Xrox bar into the brush bar. Hope fully that make sense. Then to match the top join I thought I'd do the same at the bottom or back of the arch to continue the theme.

[har05l]

Very ingenious work there Brett

Stick to your original idea and kiss , wtf would you want to go welding elsewhere is beyond me it's purpose is a scrub bar isn't it

At least a bent wing is easy enough to replace if need be

[Bilbo]

Very ingenious work there Brett

Stick to your original idea and kiss , wtf would you want to go welding elsewhere is beyond me it's purpose is a scrub bar isn't it

At least a bent wing is easy enough to replace if need be

Thank you, will see how it progresses over the next week or so. I agree with you though. Keep it simple.
Cheers Brett.

[salt36]

Where did ya get that tube bent too suit ....looks quite neat mate....I like it....would be good rather than the butt weld onto the xrox but a continuation from the top xrox tube if you catch my drift ....would give it a sleek look....

Yep I know what you mean, and I agree. I had the steel rolled in Lonsdale. I couldn't find any mandrel bends, pre bent or anyone capable of bending a tight enough bend to suit the transition from the top Xrox bar into the brush bar. Hope fully that make sense. Then to match the top join I thought I'd do the same at the bottom or back of the arch to continue the theme.

Have a look through ratstriton build thread, he made sliders and scrub bars and if memory serves me correctly, he bought some 90Degree bends that were very tight and used them....

[Bilbo]

Where did ya get that tube bent too suit ....looks quite neat mate....I like it....would be good rather than the butt weld onto the xrox but a continuation from the top xrox tube if you catch my drift ....would give it a sleek look....

Yep I know what you mean, and I agree. I had the steel rolled in Lonsdale. I couldn't find any mandrel bends, pre bent or anyone capable of bending a tight enough bend to suit the transition from the top Xrox bar into the brush bar. Hope fully that make sense. Then to match the top join I thought I'd do the same at the bottom or back of the arch to continue the theme.

Have a look through ratstriton build thread, he made sliders and scrub bars and if memory serves me correctly, he bought some 90Degree bends that were very tight and used them....

I can only find 50mm pre bent 90 degree bends. The Xrox is 48.3mm so the 50mm bends will look too big. I can't find any one who can bend this size tube without creasing or flattening it out.
I picked up some clamps from Opposite Lock to clamp the brush bars to the slider. This will make it easy to remove them if I have too.

[brodical]

That's less than a mm each ....I don't think would be noticible if your handy with a grinder and a flapper disc...

[har05l]

Why not contact the xrox manufactures Brett and see if they can help out in supplying the appropriate bends for you

[macca002]

Could you sleeve the clamps out with some zorst pipe to give you the diameter you need? Zorst might be thin enough to make work. Obviously weld the sleeves in after a test fit.

[scema74]

Nice work, great idea, I kind of agree to keep it simple as stated above,
But if you did want to make a blended join you could make a custom plugg.
Start by making a plug for each of the id of the 2 pipes you want to join, then cut and join the two internal plugs at the angle you want them to join at and weld them together.
Now you can slide the 2 pipes together on to the fabricated double ended angled custom adapter plug and secure with through bolts.
It would be a bit of messing around but, it looks great in my head, not sure if the idea in my head has come across into words though.
Like I said it would be a bit of messing around and I probably wouldn't bother to be honest.
Apologies if you just read this scratched your head and said to yourself, there a minute of your life you wont get back.

[scema74]

Nice work, great idea, I kind of agree to keep it simple as stated above,
But if you did want to make a blended join you could make a custom plugg.
Start by making a plug for each of the id of the 2 pipes you want to join, then cut and join the two internal plugs at the angle you want them to join at and weld them together.
Now you can slide the 2 pipes together on to the fabricated double ended angled custom adapter plug and secure with through bolts.
It would be a bit of messing around but, it looks great in my head, not sure if the idea in my head has come across into words though.
Like I said it would be a bit of messing around and I probably wouldn't bother to be honest.
Apologies if you just read this scratched your head and said to yourself, there a minute of your life you wont get back.

[brodical]

I no what you mean lol...I think..but it will still look like a butt joint but be removable ..yeah?

[scema74]

Yeah, look like a but join but no weld.

[Bilbo]

Spent a few more hours on the front bar ad brush bars today, just a little tidy up around the bottom or back of the bar and we are all done. The front looks even tougher now being 120mm wider and they feel solid as a rock!