Template done for a brush gaurd.

[Gary Lewis]

I'm posting this for Bill:

Gary, I was just trying to post a picture showing where the brushguard mounted on Darth and the picture uploader would not work, first it gave me a message of an invalid URL, then would not even open to browse. ???

Here is the picture, you can see from the rust stains where the unit attached, essentially right over the frame ends.

[85lebaront2]

The purpose in sending it to you was to give you and others an idea where they mounted.

[Gary Lewis]

Yep, I can see where it was, and the bolts to which it attached.

Or, were you suggesting that the shown engine oil cooler would work on the power steering?  

[85lebaront2]

It might, that is the factory auxiliary transmission cooler for the original C6. I am still using one on the E4OD.

[Gary Lewis]

THAT'S what that is!  I have one from Huck for the E4OD going in Dad's truck.

[reamer]

So yours mounts to the inside of the frame rails?  there must be a set of "3-inch spacers" in order to mount
to the rails?

[Gary Lewis]

Ron - Were you saying that to Bill or me?

[reamer]

Gary, to yous

[85lebaront2]

Ron, if that message was for me, first the picture was taken after I changed the front sheet metal and before I got the bumper off. The guard used the two lower bumper bolt holes if I remember correctly (it's been close to 7 years ago I removed it) and had fairly heavy hooks (flat bar bent to go over the bumper and bolt to the vertical portion). The lower may have had a fixed hook on it. The vertical pieces were probably 1 1/2 - 2" across the back and open inside.

[Gary Lewis]

Ron - Tomorrow I'll go look to see if I have the hardware which mounts the bar.  I tend to remember there being some but haven't seen it of late.  

[reamer]

Hmmm, I may have to make the "narrow" version available too....
It will be very interesting to see how yours mounts to the frame..

[Gary Lewis]

Here's the answer.  The bull bar bolts to the frame using adapters that look like this and are 2 1/2" x 3 1/2":




And, here's how they fit:




The bumper & frame bolt holes are 37 1/2" center/center, and the holes in these adapters are the same.  And, they are ~4" behind the lower bumper bolt, and probably go into the hole shown below, which I think is where the sway bar mounts.




Also, note that holes have to be drilled in the top of the bumper to take the tabs shown here:

[reamer]

Quote "Also, note that holes have to be drilled in the top of the bumper to take the tabs shown here":

Since I am a "rogue manufacturer of Items gone by" I may put the tabs to locate with an original bumper bolts are, and not drill into the top of the bumper.....

[Gary Lewis]

That would actually be stronger as the bull bar would then be held by bolts to the frame.  The one on top isn't all that secure as the bumper isn't very strong and can roll.

But, your hole will need to be square to take the bumper bolt.  Or, use a different bolt there.

[reamer]

Slotted holes will catch the carriage on two sides, That what the wider ones have and use the bumper "chrome capped" carriage bolts.

[Gary Lewis]

Yes, that'll work.  

[reamer]

Now I just need a milling machine......

I do have a drill press and bought an "X"-"Y" vise, I'll try milling with that....

[Gary Lewis]

That should work, but you'll need a true end mill, or cutter.  And it needs to be a single-ended one so you have some place to put it in the chuck.  Like this one, although it is the wrong size.

Drill a hole, change the drill bit to the end mill, and then gently create your slot.

[ArdWrknTrk]

If you have a press, you could just broach a square hole.
The tooling isn't too expensive.

[reamer]

Just picked up a set of Milling cutters from Harbor freight.

Broach? what is that?