gddyap
Bronco Guru
4 of us got together to build some Lars Bars last Saturday. We found a fab guy in San Jose, CA who bent the tubing and made the brackets for us. Ended up being $300 in material for each of us or $150/arm. We later found a cheaper source for the 2x.25 but we had already purchased the tube. We also could have used cheaper brackets and rod ends from someone like RuffStuff or Ballistic Fab. Got most of the cutting and grinding done. We'll get together another day to do the welding.
Slotting the tubing on a vertical knee mill.
We borrowed the welding fixture from Lars.
We chop sawed the arms to length and then used a plasma to notch them.
A bunch of grinding to the arms to make the tubing fit just right.
Here are the brackets made by the fab guy. Copy of the PolyPerformance ones that Lars used. The guy burned "L-Bars" into them as a tribute. Kind of cheesy. I may weld mine in.
Rod ends we got from the fab guy. Same size as used on the Duff arms. 1.25" I think. I think Lars used Currie johnny joints.
Slotting the tubing on a vertical knee mill.
![](http://img545.imageshack.us/img545/1910/img26160.jpg)
We borrowed the welding fixture from Lars.
![](http://img713.imageshack.us/img713/8386/img2617i.jpg)
We chop sawed the arms to length and then used a plasma to notch them.
![](http://img152.imageshack.us/img152/548/img2621y.jpg)
![](http://img232.imageshack.us/img232/6033/img26180.jpg)
![](http://img825.imageshack.us/img825/194/img2619k.jpg)
A bunch of grinding to the arms to make the tubing fit just right.
![](http://img257.imageshack.us/img257/1005/img2620x.jpg)
Here are the brackets made by the fab guy. Copy of the PolyPerformance ones that Lars used. The guy burned "L-Bars" into them as a tribute. Kind of cheesy. I may weld mine in.
![](http://img221.imageshack.us/img221/2120/img2625py.jpg)
Rod ends we got from the fab guy. Same size as used on the Duff arms. 1.25" I think. I think Lars used Currie johnny joints.
![](http://img26.imageshack.us/img26/937/img2626g0.jpg)