Sunday 28 April 2024

Garage Day - Bull-Bars

So Ev picked up some second-hand bull-bars and today we fitted them to his van. The process was straightforward but required some fabrication and a fairly high degree of precision...

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Taking off the various layers of plastic that make up the bumper.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
There were some tabs in the way and ain't nobody got time fo' that!


Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
1/4" ally angle L-brackets.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Drilling mounting holes in the bottom of the L-brackets.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Drilling the front cross-member to accept rivnuts.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
M8 Rivnuts set in situ. Note the cut-down tab behind.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
With the L-brackets fixed to the cross-members, the bull-bars were offered up and the mounting positions marked.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The L-brackets were drilled out to accept M8 rivnuts.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The bull-bars were bolted up and attention was shifted to the lower mounts.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The lower mounts engage directly with the belly-pan, so it was a simple process of marking the position on the belly pan and drilling it to accept two more rivnuts.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Meanwhile back in the 'shop, the Buell refurb is nearing completion.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The view from the 'shop.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Made a new friend!

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Work in progress...

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Excess material was removed from the L-brackets, and the edges and corners were rounded off for safety.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Big Honda still languishing in the weeds.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The two finished L-brackets, marked L & R.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
When fitting stainless steel hardwear to aluminim rivnuts, it's important to use anti-seize compound to prevent the threads cold-welding together.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
Putting it all back together.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
L-bracket in situ.

Mercenary Garage Custom Motorcycle Workshop 2024 Ev's T4 Volkswagen Transporter Bull-Bars Matte Black Mad Max Survival Bug Out Tactical Van
The finshed install. Don't expect that shiny metal finish to last long...

Images - Ev


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