My Rear Bar for XJ

[XJKEE]

Refitted the bar today to make sure it all fitted

[XJKEE]

m fairly happy with most of the bar at this stage - but - this is where Ive had my first stuff up. I'm a big advocate of the measure twice cut once rule, but this time I assumed it would be ok -

In the last lot of photos you will probably notice the rear door is not fully closed. That's because it can't.

When I cut the last pieces to weld on, I measured off the bar thinking that was where the door ends finished. In this lot of photos you can see I was about 5mm off either side , which means cutting that part right off to the correct dimensions and rewelding - Oh well. Other than that everything else has fitted well. I have also noted a few areas I can finish off a bit better.

[aus-kj]

Looks real good mate. Bit of a bugger about the door though.

[XJKEE]

Well after a night of rest and another look this afternoon, I decided to try a bit of strategic grinding - And it worked. I was only out a bit on the left side. Right side was fine.

[XJKEE]

A few more pics

[Gojeep]

Before you put a top coat on, park some where on a bit of an angle. Then see if you can still open and close it with a bit of twist in the body. You will be surprised on the older ones how much the rear moves just having a wheel up a foot or so on one front corner etc.
You can also just file the fibreglass in the corners a bit too for more clearance.

[XJKEE]

Thanks GOJEEP
Thats a good idea. The tolerances are very fine so will look at doing that. It will save a lot of time.

I still trying to decide what sort of finish to put on as topcoat - I probably won't powdercoat, but was half thingking about a wrinkle finish??? means I would have to redo the front bar as I used polyurathane on it. Anyone used it and what's it like. I'd like something reasonably tough, but with the ability to touch up from scratches etc.