Alloy Bullbar drilling holes

Richie,

There are a couple of options here.

1) Mark the position of the new holes and use a centre punch to make an indent where the hole/s will be required. Then proceed to drill a small "pilot" hole with, say, a 1/16" drill bit. Gradually increase the size of the drill bit until the hole is the correct size. However, in my experience, the biggest problem you're likely to face is that the distance between the flat part of the bullbar (where the new holes are needed) and the upper bar of the bullbar, is likely to be less than the height of your drill+bit. This would mean you would need to drill the hole/s at an angle, dictated by how close you can get the drill to being perpendicular to the base section. Of course, if you have access to a right angle air drill, then you will be able to drill the holes at the correct 90 degree angle. I don't own that type of drill (but it's on my list of "wants"). I hope I've explained that well enough. By the way, if you have good drill bits, the aluminium isn't hard to drill holes through.

2)...This is what I would do by way of an alternative..... I would calculate the difference between the existing holes in the bullbar and the "required" holes of the light bar. Lets say the existing holes are 600mm apart and the bolts of the light bar are 500mm apart for arguments sake. I would bend/weld up 2 "Z" brackets to the required dimensions and drill 2 holes in each "Z" section so that the holes in one section match the holes in the bullbar and the other ones match the light bar. The light bar will then sit (say) 30mm higher on the bullbar, but you won't have to drill more holes in the bullbar itself. Paint the new Z brackets silver or black and Bob's ya uncle!!

Cheers,

Roachie

Buy a piece of alloy box section like 50 x25 x 650 or whatever and bolt the lightbar to it and then bolt it into the holes that are there. Put a spacer underneath to allow for the nuts holding the lightbar down. Drilling extra holes anywhere is probably not a good idea or very neat.

Thanks Roachie and Tom H, some great ideas.
Will have a look on the weekend and see what I can come up with frim your good suggestions.
Many thanks, Richie.

Richard, be careful drilling extra holes into your bull bar, you may void what ever warranty you have on the bar.

Macca.