On the ORS v1.0 forum, I had a pictorial journal of the progress of the rear bar I made. I have been asked if I reproduce it, so here goes. I will have to break this into several sessions.
The tabs as the side, slide into the original bumper mounting points.
The lower / inner flat bars, will eventually mount up to original towbar mounting points. In all, it will be held in place with 12 high tensile bolts, instead of the original tow bars 8 bolts.
I didnt take any pics of how we made the facia for the rear bar. I got too involved and forgot about the pics. The facia is 1.5mm steel sheet folded to give the size and shape we wanted for the look of the rear bumper.
The sides/corners were made piece by piece, and welded and ground, and hand filed to finish of before painting.
I cannot weld, so I had a mate do that. He also did the fine cutting of the steel for the angles. I did the finish off parts, grinding back welds, hand filing, drilling, adding the extras, as well as the idea of how I wanted it to look and function.
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