Outer Limits 4x4 Board

Well as the title says cut my sills off today..WHOA, talk about full of rust. The project is coming along nicely! So what i hope to do is use mild steel (that i have left over from my old bullbar) for the "sliders" and tuck them up under the sill so they sit flush. I was then looking at buying a SNAKE bullbar. Should look good when i am done.

Project so far:

1. Cut off back section of SWB
2. Mesured up tray and working out tray
3. Cut sills off and measured up for sliders...


Will post some pics up tonight i dare say...going to go down to wynnum this arvo and take some pics..Will keep you all posted on progress...still not sure what to make the tray out of yet. Still tosing up between tube and RHS...want to keep weight down.

Sounds awsome!

I say tube!

45 the sills.

Yeah not sure about the sills yet. It was thicker metal than i thought...they were full of rust though. So I am not sure if I want to close them up again if you know what I mean...leaving them open like the way they are has its advantages...one of which is spraying the whole inside with fish oil....

klappers look at these they work well and they cost stuff all to make mine paid for them selfs the first trip http://www.shrockworks.com/zukbars.htm [/img]

They were like what i was originaly gonna make! ARB makes the same ones but for jeep wranglers!

I just enedud up with normal looking ones that cost me $15 and the welding rods!

And they have been used a couple of times too!

zookpower1 wrote:klappers look at these they work well and they cost stuff all to make mine paid for them selfs the first trip http://www.shrockworks.com/zukbars.htm [/img]

I like these but without the tube bit.

the tube bit is the bit that saved me most of the time

umm...i have already cut my sills out and they were full of rust..so there would be no way of mounting them. they certainly look the goods but. Hmm, was keen to keep everything under the car...

that popsicle zuk is sweet. my fav zook out of them all.

Have you checked out all the pics on that page klappers?

You have cut your sill, is there no sill left to mount to? (even up high?)

Ive never liked the way those sorta sliders screw to the body, but if you combined that with the way they also have mounts through the floorpan, and also bolt through the spring hanger on the chassis I think you could get sufficient mounting and also strength...? (without loosing clearance by running back to the chassis with arms etc?)

other than that, I would go tube bends from underneath back to the chassis, and RHS to flush fill the cut sill.

no..most of the sill was full of rust..good time to get rid of it i think. Having a good look at the photos, that is a brilliant idea, looks like the goods to me. But, and this is the doozy, I have cut the sill off....and i have cut it off high so that I could mount the tube without to much trouble. Plus the sill was also full of bog, so it would have been a wast of time bolting it on there...anyways i think what i will do is get some tube to make the sliders out of and then mount a bar just outside the cab (just below the door)...should work out okay..will post some pics of where i am at. that way you guys can actually see how much i have cut off.

If you've already cut the sills out you would be best off 45ing it (the plate to cover the gap) and mounting the sliders off your chassis rail. You could run the tube on an angle up that follows the 45 sill and have full protection. Would look good too.

=SKB= wrote:If you've already cut the sills out you would be best off 45ing it (the plate to cover the gap) and mounting the sliders off your chassis rail. You could run the tube on an angle up that follows the 45 sill and have full protection. Would look good too.

thats the plan stan

that seems like the most logical solution. Because there is so much rust in the bottom and the face of the sill, that i had to chop it off and then 45 seems like the way to go. How thick does that plate need to be....2mm 3mm??

I had 4mm on my old tub for the 45ed sills and it still bent.

umm the thickness of the 45 should be the same as the other faces of the sill because it will only be as strong as the other sides...

took some photos..will post them up tonight if i get half a chance...dont have a USB cable down at mum and dads so cant do it now

as you can tell by the pics..shes a bit rusty mate...will be sourcing some 2mm plate to 45 the sills and i will probably fish oil the inside of the sill before i weld and add a drain hole.

Yep theres rust in there! What are the plans for this one? I thought the one as your avatar was your rig? Do you have 2 now? Like the custom decal's!

stripped the yellow one, and now building up this one..this one will be legal..unlike the coiled yellow one..

Klappers wrote:stripped the yellow one, and how building up this one..this one will be legal..unlike the coiled yellow one..

tragedy u should have sold it to me!!!!

there was nothing good left on it mate:)

chassi and boddy thats all you need for a starting point!

true but i wouldnt have used that chassis mate....

that was alot of rust thats not good

RHS, here is what I did on one





The floor still had to be trimmed and replated, it is a lot of work but well worth it i reckon, i want another zook

I like the look of Bubs' RHS sills

They look nice and neat, solid and fairly simple to do. With the flat face of them and the strength of the RHS, they are harder to dent and could be used with a hi-lift jack.

Bubs' do you just run a weld along the top outside face and another along the inside lower face? I assume that these are the only accessible points to attach, and with the force exerted towards the vehicle with any impact spread along the full length of the bar that this would be strong enough to take as much force as the weight of the Zook would exert. (eg falling from on it's side and coming down on a rock).

What are the specs on the RHS they look a good size? Amost standard to the untrained eye.

yeah the rhs does look good for sure. Was keen to keep the sill open to prevent more rust thats all. It will either be 45 then sill protected or just rhs...choices choices...

yeah the rhs does look good for sure. Was keen to keep the sill open to prevent more rust thats all. It will either be 45 then sill protected or just rhs...choices choices...