Member Since: 21 Oct 2016
Location: kent
Posts: 13629
So now thanks to @ Rob698 for the bolt sizes
Bolt sizes:
L: 70mm with a 22mm effective thread, Dia: 8mm and 13mm head
Washers:
OD: 25mm, ID:9mm and 1mm thick
Sleeves sizes:
2 x L:48mm, OD:14mm and ID:10mm
2 x L:37mm, OD:14mm and ID:10mm
Have started trying to repair my A bar , alas never done this type of repair before , glued the small piece in and will leave it for a few days , took me forever to get it completely level
Think though once set I’ll have to cut a V groove in the front of that piece with a Dremel, got some plastic filler, textured paint and some primer months and months ago, thank god it’s still in date
However I’m not sure if I’ll need to spray a top coat over the textured paint and then a Matt lacquer , suppose similar to what I done with the scuttle panel
Will start with filling it and go from there , hopefully this may be of interest / help to someone
19th Jul 2021 7:14 am
Globetrotter448
Member Since: 21 Mar 2017
Location: Londonderry NSW
Posts: 1782
Glad to see you have the measurements. The required holes seem a bit of overkill at 33 mm for 14 mm sleeve.
19th Jul 2021 10:04 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
You and me both mate and indeed ur so right , overkill with the 33mm holes , suppose the only thing I can think of is bolts going in at an angle
But at least we can drill something like a 15mm hole and increase them if req
As I need to get the bolts, sleeves and washers I’m thinking of the sleeved bolts , alas though just need to find the right size
Been looking on eBay but alas so far no good as there either to large or to short , have emailed several companies with the dimensions in case they have some
If not wondering about using nylon sleeves to elevate the worry of rusting , also will measure the hole as I’m not sure if the sleeve goes in that or the M8 bolt fills the hole , assume because the A bar is angled the sleeves go long at the bottom hole and and short on the top one
Thks again and will be good between all of us to then finally nail down the size of drilled holes req etc
Will see what that repair looks like after I’ve removed the timber and clamps , then V shape the front to accept some of the plastic filler , know that will take me some time to get it just right
19th Jul 2021 10:18 am
Globetrotter448
Member Since: 21 Mar 2017
Location: Londonderry NSW
Posts: 1782
On the repair, I have seen advertised on Ebay that they have instant glue cured by a UV light that is super strong.
19th Jul 2021 10:29 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
Many thanks and that’s very interesting , fingers crossed the one I’ve used will work , says one there it can glue on spoilers so hoping it will be strong enough for this small repair
Another section I’ll be very nervous about is the textured spray , got 3 x cans of that , primer and the filler
Have managed to get hold of a number plate plinth that goes on front of the A bar so will try it on that first to ensure it binds properly including using a Matt lacquer coat to ensure there’s no reaction
19th Jul 2021 10:36 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
Example picture of the number plate plinth , going to drill right through so can then bolt the number plate on and then bolt the plinth onto the A bar , just thought then it won’t come unstuck in being bolted on
19th Jul 2021 10:41 am
SN
Member Since: 03 Jan 2006
Location: Romiley
Posts: 13710
This brings pack somewhat panicky memories from 15 years ago when I did this to my VERY NEW D3
Cutting the large holes in the front bumper is definitely a particular stress point!
Click image to enlarge
Steve N | 21MY Defender | 08MY Discovery 3 (history) | 06MY Discovery 3 (ancient history)
20th Jul 2021 11:09 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
I bet it was, same when fitting a RAI with drilling holes in a perfectly good wing
Have carried on with repairing this A bar, cut a groove in and filled it with some filler , also done a test spray on the back of the number plate plinth , I’ll then use a primer and then the textured paint over the entire A bar, fingers crossed will come out ok
Think I’ll use an electric sander as I think it will take ages otherwise
20th Jul 2021 11:22 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
Done a bit more , repair I can see is just below the old textured paint , gave it a miss coat of primer
Just hope I don’t mess it up , needs just a little more filler , will then spray the entire thing with primer and lastly spray the textured coat on
20th Jul 2021 5:42 pm
Globetrotter448
Member Since: 21 Mar 2017
Location: Londonderry NSW
Posts: 1782
Looking good
20th Jul 2021 11:17 pm
D1SCD
Member Since: 13 Feb 2013
Location: North Yorkshire
Posts: 407
gstuart wrote:
Hi phil
Alas that was a picture from someone else’s disco
The very special brackets I got I’ve coated with Dinitrol to keep them well protected and they line up to mm perfect
Hi Stuart.. I realise I'm resurrecting an old thread, but I don't suppose by any chance you happen to remember when making the brackets, what the distance was from the central mounting hole where it bolts to the crash bar to the bottom A Bar mount hole (between centres)
Also, the little tabs welded to the upper part of the bracket. What do these do, are they really needed ?
Lastly... Thank you so much for all the info you and others have provided in this thread regarding measurements etc. What a fantastic forum it is.
31st Mar 2022 11:16 am
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
Hiya
Does this help u at all , I also used an old impact bar which I laid on the ground and then got the angles
I’m afraid these are the only pics and drawings I’ve got , I think those tabs are to help support the A bar
Other picture is where I laid the A bar flat on the ground ti get another angle , hope it makes sense
Fingers crossed there of some use to u
Click image to enlarge
Click image to enlarge
Click image to enlarge
Click image to enlarge
A bar laid down flat and level to get angle
Click image to enlarge
Click image to enlarge
Impact bar laid flat and level on the ground
Click image to enlarge
Click image to enlarge
31st Mar 2022 11:54 am
D1SCD
Member Since: 13 Feb 2013
Location: North Yorkshire
Posts: 407
Fantastic - Thank you, a great help in my quest to make some brackets
31st Mar 2022 12:10 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
Also just found these pictures that were online, where the A bar has been bolted directly onto the bumper
Plus I’m pretty sure the D3/4 bumpers are a different shape but as you’ve got a D3 u won’t have to worry about that
Spotlights I got a pair of these which just about fit, there 9 x inches in diameter , just wished to share so u had some form of scale on what size u can fit
Lastly I managed to get hold of a complete genuine spotlight loom, will u be making up ur own or buying a complete genuine loom plse , plus there should be a connector inside the engine bays fuse box , genuine loom connects to it
Last edited by gstuart on 31st Mar 2022 12:20 pm. Edited 2 times in total
31st Mar 2022 12:13 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13629
D1SCD wrote:
Fantastic - Thank you, a great help in my quest to make some brackets
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