Anti wrap fab and install

MangoMan · 01-17-09, 08:29 PM

Finally got some time over the holiday season to make and fit an anti wrap bar. Can't believe the difference! Even feels better on the road. I have included some photos and comments for anyone interested.
Below is the chassis mount (made a duplicate of everything to go into a mates truck) made from 50x50x3 SHS. Picked up a shackle and bushed mount from the local trailer supplier.

jvazquez53 · 01-17-09, 08:32 PM

Pictures installed???

MangoMan · 01-17-09, 08:34 PM

Cleaned chassis and welded mount on. (I hate welding upside down!). Cut out some cardboard templates for the diff mounting brackets and blew them out of 8mm flat bar with the oxy.

MangoMan · 01-17-09, 08:40 PM

Purchased a rose joint from the local bearing supplier and machined up two sleeves to locate it in the centre of the shackle. Should have been a five minute job but my lathe is very dodgy. The centre hole was slightly off but not to worry. Also bored and tapped a thread into some round bar to weld into the end of the wrap bar.

MangoMan · 01-17-09, 08:44 PM

Was going to move the handbrake mount over to the left as Toyota have conveniently drilled two sets of holes but after checking the handbrake cable length on full travel i decided to remove it completely and instead weld a small bracket onto the diff brackets.

MangoMan · 01-17-09, 08:48 PM

Turned up some round bar to take the rubber bushes at the diff end of the bar. Would have liked a notcher but a hole saw did the trick for profiling the ends of the bar.

MangoMan · 01-17-09, 08:56 PM

Did a dummy fit-up next to determine the lengths of the top and bottom bars. Once cut, they were reinstalled and the top bar welded to the rose joint mounting piece. The bottom bar was then marked and cut to fit the top bar. Tried to keep the bottom bar as long as possible to act as a tailshaft guard as well. Then cut some of the left over 8mm flat bar to make a brace between the top and bottom bars at the diff end.

MangoMan · 01-17-09, 09:02 PM

Time for final fit-up and pre paint test. Adjusted the rose joint until the angle of the shackle was dead vertical. Will install a locknut on this once i have tested it under full travel. Handbrake cable seems to clear everything ok and does not get tight under full travel anymore.

MangoMan · 01-17-09, 09:15 PM

Killing two birds with one stone. Much quicker to make two sets at the same time! And, of course, wouldn't be complete without an action shot. Many thanks to all the people with similar posts as it made the planning so much easier.

chicago · 01-17-09, 09:34 PM

Nice job!
Looks like a fun test run too!

Chicago

moosecruiser · 01-17-09, 10:22 PM

anything u would change ??

MangoMan · 01-17-09, 11:00 PM

Would like to have cut some holes in the flat bar that i welded in the rear of the wrap bar before i welded it into place but using a hole saw with a hand drill is tedious and time consuming at best. I do have a mill but not at home so i might remove it at some stage and add the holes - although they really are just for looks.

NLXTACY · 01-17-09, 11:15 PM

Dude, I need your garage doors!!

Dieseler · 01-18-09, 01:22 AM

Will the shackle part of your system hit the transfer case, looking at the pics it looks as if there is that possibility not sure if there is forward travel or does it stop short of contact.

MangoMan · 01-19-09, 03:20 AM

No the shackle can move around 60mm forward before it hits the mount. Hard to see from the photo but it is actually about 100mm away from the transfer so i can remove the box (auto) if need be. I tested it on the hoist at work and the total movement is 15mm in either direction so there is tons of room.