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Old 05-24-2009
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Roll Bar Mounting?

This is my next project i want to complete. Just like in the pictures i want to mount them directly on the sides of the bed.
Question is, how would you all mount it for it to be solid?
Ive been trying to come up with ideas but now i cant think of anything. I know that you all must be saying, "just mount in on the wheel wells and inside the bed just like everyone else..." Im always halling my quad when ever i leave home and i dont feel like getting a trailor.

So any advice would be great... Dont mind the info in the picture for the thickness, thats too soft i know.. how thick would you guys use for the tubing?

Also, i will probably add some loops for straps at the base of the tubes closest to the cab where it mounts to the bed. And once completed im going to have it painted black.



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Old 05-24-2009
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I would use 3-4" tube and I would just weld a piece of gusset to the bottom of the tubes to sit on the bed rails and then put some bolts in through the bedrails to hold it on.
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Old 05-24-2009
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I though about that putting a 1/2 " bolt, but would the soft sheet metal of the bed be able to hold it good?
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Old 05-24-2009
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Use a big washer on there and it will hold it. From top to bottom is should be bolt head, Washer, gusset, bed rail, washer on the under side of the bed rail and then a nut.
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Old 05-24-2009
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Alright, thanks. I got 2 options though, when i seal the tubing underneath, i could weld the bolt right in the center of the tubing.
Or i could have a long plate that goes past the tubing and have the bolt accessible. What would be better?
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Old 05-24-2009
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I think i would rather have the metal go past the tubing and have it more accessible. It may not look as good, but it should give it more stability and strength. I think I would put 2-4 bolts in the gusset around each tube. Two in the front of the tube and two behind it.
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Old 05-24-2009
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Space might be kinda tight, so i could use just one piece of metal and bend it to form the shape of the bed and use it as the washer. so it would look a little like this(Bracket, bolts, Tubing, Bolts, Bracket)>>>> [:O:]
Any idea for the thickness i should use for the tubing?
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Old 05-24-2009
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That's what I was thinking, but I think you need a washer on there too, even if it's a small one you need something. As far as the thickness of the tubing 3-4" for the diameter and the thickness of the metal itself, that just depends on how strong you want it to be. Also do you plan on using it for a light bar too?
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Old 05-24-2009
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I didnt think of using lights on it. Im going to put 2 extra lights on the bumper eventually (thats another long project) but for the roll bar, im keeping it pretty simple. Solid enough for me to strap stuff to it and put weight on it...

Last edited by Ranger06Fx4; 05-24-2009 at 11:09 PM.
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Old 05-26-2009
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I would personally just use 2" .120 wall DOM. Plenty strong and doesn't take up much space.
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Old 05-26-2009
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Im currently making a prototype out of PVC right now. i got 2" pipes and i think thats what im going to go with.. 3-4" might be a little too big for a ranger. I will post some pictures when its done.

Cancel that plan. Its not exactly working out like i had planned. Im just going to wait till later this summer when i got more time to get back to it and just go ahead and do it with 2 or 2.5" tubing.

Last edited by Ranger06Fx4; 05-28-2009 at 08:25 PM.
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