My XJ rails
 

I finally started my rails project on the weekend. I've used an inner rail of 50x50x4 SHS and an outer rail of 32NB medium wall pipe. I was originally going to bend the pipe but found my local steel supplier had the corners that I could just weld into position - and they will be much neater once it is all finished.

Here are some pics of the process.

Using these pre-fabricated bends meant I just had to focus on a good solid weld (not an issue!). The smaller pipe shown against the square inner rail has been cut at a 30 degree angle so the outer round rail will sit up (see later pics). As a result the outer rail is about 1370mm - 1380mm long.

http://www.ausjeepoffroad.com/forum/...7&d=1218367025

http://www.ausjeepoffroad.com/forum/...8&d=1218367112

http://www.ausjeepoffroad.com/forum/...9&d=1218367112

http://www.ausjeepoffroad.com/forum/...0&d=1218367112

I need to bolt the base plate to the frame rails of the XJ, and note that it doesn't appear I can get inside the rail with my fingers to put a nut. My preference is not to weld these to the body, so I'm wondering if someone can let me know if there are other options?

The JKS website shows "self tapping bolts" for their rails which are about 8mmx25mm. My local fastener mob doesn't have a self driller up to that size (something with fine thread).

I went al the way through the frame rail with a piece of tube in the middle to stop it crushing and a plate on the back, tricky around the brakelines but other than that not too bad. I thought about welding the tube to the plate but am just floating it in there as it was hard enough to get the plate on the back on the passenger side anyway.

Cheers
Steve

I tacked a bit of wire to the nuts and slid them down the inside of the chassis rail on my xj a bit of messing around though

coming along nicely. I was spending a bit of time grinding/sanding/smoothing the curves of the bar until it dawned on me - these aren't "race spec", these are bash spec! So I started painting...

I found a bolt type called a rolling screw for the chassis rails. The thread of the bolt looks like a tapered tap. You drill the recommended hole size (based on the bolt, and the thickness of the material you are bolting into) and then just screw the bolt into it which will roll its own thread - magic! Mine are M8x30.

http://www.ausjeepoffroad.com/forum/...6&d=1218605249

http://www.ausjeepoffroad.com/forum/...7&d=1218605249

http://www.ausjeepoffroad.com/forum/...8&d=1218605249

http://www.ausjeepoffroad.com/forum/...9&d=1218605328

http://www.ausjeepoffroad.com/forum/...0&d=1218605328

Looking good

Any close ups of the bolts you talk about and where you got them from? Also how much were they?