Alloy bullbar repair

[paintmiester Lurker Find all posts View Profile Close paintmiester]

After a minor swipe of a safety rail, thanks to trying to avoid someones mutt!!!!! I am in a bind regards the original bar.
I have a 2001 50Th Anniversary 3.4 V6 and the panelbeaters rang to say Toyota no longer supply that bar! To get anything remotely close is going to cost $1900+++, which the insurance mob may not cover!
So am considering having the bar repaired. The right side has a slight deflection in it and there's a gouge in the lower front section. Surely the bar could be straightened and the gouge mig weld filled and smoothed.

Has anyone had this done and more importantly, does anyone know of a business in the Newcastle area who does it?

Appreciate any advice and help offered in this regard.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Re: Alloy bullbar repair

The gouge should be no problems to weld, My father in Law kindly gouged my soverign bar when he backed into it. I welded it up filed it of smooth, cleaned it up with varying grades of wet and dry, once finished it was impossible to see the repair.

Welding up gouge.



I TIG welded it rather than MIG, not sure about the deflection though, your panel beater would be the one to ask about that.

Cheers Andrew

[paintmiester Lurker Find all posts View Profile Close paintmiester]

Re: Alloy bullbar repair

Thanks for the heads up Andrew.
The panelbeaters take on it is to just replace it. They reckon its not worth the trouble to even try and repair. Toyota sent out a replacement bar but it's of a lesser standard than the original; no fog lamp fitting point and lower frontal profile. Not what I wanted.
So I have to try and find a local repairer to fix the original bar or but a new one of a slightly different style than the original. The hassle is I'll be out of pocket for an extra $600, not something I'm happy with.

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

Re: Alloy bullbar repair

Your profile says QLD but the only Newcastle I know of is in NSW - where are you?
(I know a specialised alloy welder in Sydney.)

[paintmiester Lurker Find all posts View Profile Close paintmiester]

Re: Alloy bullbar repair

Live in QLD but I am working in Newcastle for the next 4mths or so. Will be doing at least two trips back home between now and Jul/Aug so a bar would be preferred before hitting the road.
Would rather someone local to help cut down on transport etc and any problems that may come up with potential errors etc.

[paintmiester Lurker Find all posts View Profile Close paintmiester]

Re: Alloy bullbar repair

Update:

the panelbeater sent some pics of the bullbar to a bar repairer in Sydney. The response was a no go! Bugger!!!
So I'm now stuck with trying to decide which way to go. Leave the bar as is, keep looking for a second hand unit through wreckers or keep looking for someone who can fix it.

Any suggestions would be appreciated.

[matt150 Avid PP Poster! Find all posts View Profile Close matt150]

Re: Alloy bullbar repair

Hit ebay for a 2nd hand steel bar and fit that ?

Just a suggestion...

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

Re: Alloy bullbar repair

Let's see the pics!