DIY Rear Bar and twin wheel carrier

[Trekrider Banned Find all posts View Profile Close Trekrider]

Hi BrettM, yes, it was Safetech and they charged $150 to do the whole lot. I have to get the left arm re-done since I welded on the HiLift bracket and that's $30. Thanks for the offer - I will have to remember that

[Trekrider Banned Find all posts View Profile Close Trekrider]

Finally got round to doing some more work on the rear bar. First up - got the wiring sorted and joined in a waterproof junction box:



Managed to get some tread plate for a good price (that's what has been holding me up). Cut this to fit the top of the bar over to the rear of the body:

[Trekrider Banned Find all posts View Profile Close Trekrider]

I used a saddle clamp to hold the cables going to the right arm in place:



Had to make up a bracket to hold the right side rear quarter in place:

[Trekrider Banned Find all posts View Profile Close Trekrider]

The left side rear quarter was easy to hold in place - I backed up the push in plastic thingy with a screw at the bottom into the existing bracket:



That's pretty much it now - just need to come up with a way to hold the black plastic trim in place and probably get some pinchweld for the edge of it:

[1tuff4b Member Find all posts View Profile Close 1tuff4b]

Looks better than a bought one Barry. Joe (at Safetech) does an awesome job and looks after his cashie clients . I used to use him all the time when I had the business down there.
Can you not use blask Sikaflex to hold the plastic trim in place?? You could of also put an upwards kick on the treadplate so that it meets with the panel work.

Hi BrettM, Ill put an order in for a bar whilst you are knocking one up, I'll need it painted silver tho

[BrettM Member Find all posts View Profile Close BrettM]

Hi Trekrider, I have finished my wheel carrier off and I did away with that plastic trim by bending the tread plate up at the back and removing the brackets that held the old plastic bumper on. I will post up some pics this weekend. By the way way I spotted you a couple of weeks ago, you were pulling out from Malibu road you were behind me at the traffic lights near rocko city then you went right into council ave I was in the white prado ( wheel carrier wasn't fitted at the time ). 1tuff4b I don't mind making another if your keen, just depends on how much you want to spend. I made mine a bit different to Trekrider but if your keen then your more then welcome to come have a good look at mine and go from there

[Trekrider Banned Find all posts View Profile Close Trekrider]

Hi Brett,

I was going to bend the edge of the tread plate up but still planned on using the black plastic trim as it covers up the rear door stay nicely. I have no way of bending sheet material so in the end left it flat.

I've been thinking about how to do it and taking MLCs comments about his I think I can mount a piece of flat bar across the original bumper mounting brackets and attach the trim to that - need to have a closer look to see.

[Trekrider Banned Find all posts View Profile Close Trekrider]

Hi BrettM, yes, it was Safetech and they charged $150 to do the whole lot. I have to get the left arm re-done since I welded on the HiLift bracket and that's $30. Thanks for the offer - I will have to remember that

Only charged me $20 in the end - bargain

[BrettM Member Find all posts View Profile Close BrettM]

Bending the plate was easy, I just sliced down the back of the plate where I wanted to bend with a 1mm cutting disc then bending was easy just need to run a weld along the cut to stiffen it back up which I will do on Saturday

[Trekrider Banned Find all posts View Profile Close Trekrider]

Bending the plate was easy, I just sliced down the back of the plate where I wanted to bend with a 1mm cutting disc then bending was easy just need to run a weld along the cut to stiffen it back up which I will do on Saturday

I don't have the facilities to weld aluminium so not an option for me. I'd like to see some photo's of how you made your bar though.

[derek11 Advanced Member Find all posts View Profile Close derek11]

one of the best DIY jobs i've read so far, a real credit to you Trekrider, alot better than the known brands out there and its set up to how you want it, wish i had the time to try this.

[Trekrider Banned Find all posts View Profile Close Trekrider]

Thanks Derek.

I worked out how I was going to mount the black plastic trim - I removed the two brackets that hold the OEM bumper and made up some brackets to fit in the same places:





I then just screwed the trim to the new brackets:



Refitted the rear door stay:

[Trekrider Banned Find all posts View Profile Close Trekrider]

Note the pinchweld fitted to the edge of the trim.

Shut the rear door and finally the job is complete

[FatTruckie Lurker Find all posts View Profile Close FatTruckie]

interested in doing this myself unfortunately the links for the photos bucket of the photos are no longer active I was wondering if I could possibly get some photos to give me some ideas. Has anybody else made or had made full custom rear bars.