Outer Limits 4x4 Board

Hai,

So after I had my rig recovered from teh theft and I sort of tallied the damages, I decided to keep the thing. My cheezy bar and uber tuff draglink just arrived through the week and I've relegated fitting duties to my old man.

Being an 1988 GQ SWB its been used a bit and I naturally expect there to be a smalllllish twist in the chassis, or at the very least things not to be perfectly square as they were when it got rowed over on a boat from japan.

Anyhow the old boy is telling me he is having some trouble getting the bolts to perfectly allign and go through teh holes, we're talking in the order of a mm or so. My suggestions were that cheezys things are most likely designed in CAD for a pristine chassis, not an grubby 88 well used yellow fugly thing.

My questions aree..

What have you guys done in cases where things were slightly off.. with regards to chassis mounting and pre bought gear ? Any tips... ??

I had a similar problem.

all bolts that can be put in loose be put in until finger tight. ratchet strap around bar/chassis to twist in direction needed.

or just be dodge and reem the bar out with a drill

I had the same problem when I fitted my ARB bar to the GQ. I put as many bolts as I could in and finger tightended them and a couple of bolt holes were about 1mm out and woulnd't go in. I got a die grinder onto the job (be careful not f$%K the thread though) with a grinding nose and it worked a treat.

yeah my cheezy bar had to be reamed out also, guess it makes for a tight hole

my arb bar was out due to a chassis twist, needless to say nothin a sledge hammer cant fix

The bars can warp when they are powdercoated due to the heating and cooling process. I made my bar and it fit perfectly until I had it powdercoated and had to make a few adjustments. All Cheezy's and ARB's bars are powdercoated so you would expect they are not going to be perfect unless they are placed in a jig to powdercoat them. My sugestion is just ream the hole out a bit or mould the chassis or bar a bit with the sledge hammer.

True the bars are cut and folded on cad and welded on a jig. The bar holes and chassis section are the same every time, even after powdercoat.
We also have probs at times fitting onto chassis that have been tweeked and have too spend some time squaring up the chassis ends back too square instaed of diamond. We have always made our bars a close fit too the chassis so there isnt any rocking on the bolts as our bars started life as comp bars too be put under alot of stress.
Spend some time hammering the chassis end as square as you can get. If the bolts still dont line up die grind the holes slightly, when all the bolts fit take the bar off prime and paint the ground areas.
If you still have probs give me a buzz at work next week. (Im off this week due too setting up for OZ Rock).

Thanks everyone.

Yer after a bit of belting away at the chassis it all eventually lined up.

Did I mention it looks hawt