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  • AJ120 Rear Bar / Dual Wheel Carrier

    These are available to purchase, have a look here
    http://www.pradopoint.com/showthread...-Wheel-Carrier
    Or email me direct at aj4x4 at bigpond dot com No spaces in email address and replace the at with @ and the dot with . to stop the spammers.

    OK, I know a lot of you are keen to see the rear bar I have been working on. It’s been a lot harder than I expected to get it developed, mostly due to a lack of equipment on my behalf that would make it easier to reproduce each part accurately enough to produce these, which is a lot harder than a once of custom job.

    Anyway what I wanted to achieve that is different to most if not all other bars on the market is the following.

    1. Rear bar to extend all the way to the wheel arch.
    2. The option to have a single wheel fitted so that it lines up in the original spot so it looks neater. Ideally a reversible mount so it can also accommodate a second spare without needing to change arms.
    3. A neat finish where the bar meets the body work, I have not really seen one that I have particularly liked the finish on.
    4. Off course all this needs to be achieved at a realistic price and with my limited workshop.

    What I wanted to avoid was things like this poor fit on the Kaymar.



    And pretty ordinary fit and finish like on this one.



    Cheers Andrew
    AJ120
    Out of control poster!
    Last edited by AJ120; 12-03-2014, 09:46 AM.
    [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

    [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

    [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


    [SIGPIC][/SIGPIC]

  • #2
    After seeing Treky’s bar build I decided that following suit and using RHS for the main bar was the way to go. After much agonizing about how to mount it and the various towbars that might need to fit with the bar I decided intergrating a towbar would be the best way to go. Lots of research followed about the legalities of that and the testing needed but I should be able to get it tested and certified without much trouble once a prototype is complete. Unfortunately the testing involves stressing the bar to the point where it is no longer serviceable so it will have to be scraped!

    Pics are a bit out of order as I missed photographing a few steps. Mounting it was a real headache given if I sell these they need to be able to be fitted without the need for major modifications to the vehicle, so at this stage there is no drilling or welding involed as it utilises existing mounting holes. I may offer the option to weld on a small bracket that whilst should not be needed would add a considerable amount of strength to the mount, but still working on that and other options.

    Anyway, always fun cutting into the bodywork on your pride and joy, more nerve wracking when it’s a prototype and no guarantee that place I cut it was going to be the where it needed to be once finished.






    So far so good as far as the cut goes, I did lower the bar slightly (twice) from the original plan so my cut is about where it need to be once I fit some pinchweld to neaten it up. As you can see, side wings all the way to the arch. I have made and remade the wing quite a few times now to get it a bit more shapely. A lack of equipment that I have as well as local engineering works lacking quality equipment made this a pretty a difficult little part to get right, but we got there in the end.




    I’ll add more later.

    Cheers Andrew
    AJ120
    Out of control poster!
    Last edited by AJ120; 15-07-2014, 04:08 PM.
    [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

    [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

    [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


    [SIGPIC][/SIGPIC]

    Comment


    • #3
      A couple more pics!






      I didn't take a pic when I had the rear bumper fitted at one stage but the pic below shows the final cut for the rear bumper, so with some pinch weld run right round the entire cut the step into the rear should remain the same as original using the original plastic trim to make it as neat as possible.




      I'll add more as I take more pictures.

      Cheers Andrew
      AJ120
      Out of control poster!
      Last edited by AJ120; 15-07-2014, 04:10 PM.
      [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

      [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

      [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


      [SIGPIC][/SIGPIC]

      Comment


      • #4
        Originally posted by AJ120 View Post
        Anyway what I wanted to achieve that is different to most if not all other bars on the market is the following.

        2. The option to have a single wheel fitted so that it lines up in the original spot so it looks neater. Ideally a reversible mount so it can also accommodate a second spare without needing to change arms.
        So far so good with the reversible arm on the RHS, here are a few pics with it set up with one spare only, and then set up to take 2 wheels. I will get some pics with the 2 wheels fitted at some stage.

        Wheeel lining up with original position.



        Reversible fram on RHS and then both arms fitted for fitting of 2 spares.





        Cheers Andrew
        AJ120
        Out of control poster!
        Last edited by AJ120; 15-07-2014, 04:12 PM.
        [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

        [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

        [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


        [SIGPIC][/SIGPIC]

        Comment


        • #5
          Few more updates on the rear bar.

          I got some struts for opening the swing arms, they do a ice job but I think are a bit underpowered, It was pretty hard to work out what strngth to get, started with a 150N unit which is fine on the flat but I think will be not up to the job when on an angle, so will look at getting them regassed around the 250N mark should be sweet.

          Also cut some T slots for the high lift.

          Recessed the tail lights, in the pic the light is just hanging in there, so not quite fitted as neatly as it will end up.










          Cheers Andrew
          AJ120
          Out of control poster!
          Last edited by AJ120; 15-07-2014, 04:14 PM.
          [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

          [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

          [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


          [SIGPIC][/SIGPIC]

          Comment


          • #6
            After the last fit up with it all welded together, as opposed to being tacked I was still wasn't happy with a bit of movement in the bar. I tried pretty hard to make it as strong as needed using only existing factory mounting points but in the end I wasn't entirely happy with it, so I welded a small braket to the rear of the chassis on either side which really doubles the strength.

            No bracket welded





            Clean the paint of the chassis for a good weld



            Weld the bracket in position and drill for an extra bolt



            Hopefully I get it cleaned up and then off to the powder coaters, hoping to have it painted and ready for show at Mount Pleasant next weekend.


            Cheers Andrew
            AJ120
            Out of control poster!
            Last edited by AJ120; 15-07-2014, 04:16 PM.
            [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

            [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

            [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


            [SIGPIC][/SIGPIC]

            Comment


            • #7
              Getting close, just need some pinch weld to tidy up the body work. I have a new slimline number plate coming to be centrally mounted and cover the 4 holes in the middle of the bar. Also need to mount the trailer plug, I have ordered a flat style plug rather than the large round that is common here in SA.

              Mud flaps were a rush job before testing it out on the weekend so will tidy them up as well.











              Still have to make a single jerry can holder that will be what I normally run on the LHS

              With two wheels fitted





              Cheers Andrew
              AJ120
              Out of control poster!
              Last edited by AJ120; 15-07-2014, 04:25 PM.
              [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

              [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

              [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


              [SIGPIC][/SIGPIC]

              Comment


              • #8
                A couple of shots of the Mudflaps I made.






                Cheers Andrew
                AJ120
                Out of control poster!
                Last edited by AJ120; 15-07-2014, 04:20 PM.
                [COLOR="#FF0000"]So Long and Thanks for all the Fish![/COLOR]

                [url=http://www.4wdadventurers.com/showthread.php?3840-AJ-s-120-Prado]MY PRADO AND DIY CAMPER TRAILER[/url]

                [url=http://www.4wdadventurers.com/showthread.php?3975-AJ-s-79-series-Cruiser-Ute]MY HZJ79 Landcrusier[/url]


                [SIGPIC][/SIGPIC]

                Comment


                • #9
                  AJ120,

                  Thats very good! well done mate!

                  ive been waiting a while for a rearbar like the 150 rearbar that extends to the mudflaps looks like this is the one!

                  Cheers Octane

                  Comment


                  • #10
                    Looks good so far Andrew. I wasn't brave enough to cut the body to extend the bar to the mudflaps when I made mine

                    Comment


                    • #11
                      looking good aj.

                      is it not possible to reduce the rear over hang anymore?
                      i was looking at using some C channel that fits over the chassis, and the reciever underneath like the old Hayman reese towbars.

                      i will be watching. cheers
                      SIK-120
                      2008 Toyota Prado 120
                      ...with a few bits and pieces on it...

                      Comment


                      • #12
                        Me like, what I see so far Andrew. My sliders are excited at the prospect to have a relative down the back soon...
                        [B]Robert
                        [URL="http://www.pradopoint.com/showthread.php?32134-Gumboot-s-120-D4D-GXL"]2007 D4D GXL Prado[/URL][/B]
                        [I]"The true measure of a man is how he treats someone who can do him absolutely no good."[/I]
                        [SIGPIC][/SIGPIC]

                        Comment


                        • #13
                          Originally posted by gumboot View Post
                          Me like, what I see so far Andrew. My sliders are excited at the prospect to have a relative down the back soon...
                          Yes I have heard that you are looking to replace a rather 2nd hand looking rear bumper following the last CityView trip Robert
                          2004 V6 Grande. BLACK -

                          Comment


                          • #14
                            Major work in progress - great to see the thought that has to go into this and how complex it can be. Can't quite tell but has it reduced the departure angle? Will the final product need the tail end chop or is that for the prototype only?
                            Cheers
                            DocK
                            2007 Prado VX D4D, With a lot less options lately!

                            Comment


                            • #15
                              Originally posted by AJ120 View Post
                              the pic below shows the final cut for the rear bumper, so with some pinch weld run right round the entire cut the step into the rear should remain the same as original using the original plastic trim to make it as neat as possible.

                              This will make it look very neat Andrew but I've found with mine that standing on the aluminium tread plate is a great way to get up to the roof rack. Are you putting anything under the plastic trim to fill the void so that standing on it doesn't cause a problem?

                              Comment

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