How to Make a Bull Bar

by Contributor

Bull bars help protect the front end of a vehicle without covering over the detail of the grille and other features on the front end. Typically, it is installed on a truck or SUV. A number of these are commercially available, though custom bull bars can give a unique look to the front end.

Create a rough sketch of the bull bar design. Once the general idea is realized, determine the dimensions and curvatures needed. Also be sure to locate the cross bar and any desired skid plate.

Determine what metal to use. Aluminum is a good lightweight metal to use for this purpose, though steel will provide great strength and lend itself to chrome plating. Just be sure the tubing and metal plate are of the same metal.

Examine the front underframe of the vehicle and check for any provisions from the manufacturer to mount a bull bar. If none exist, locate where holes will need to go. Mark the hole locations and drill when the design is finalized.

Cut mounting brackets from the metal plate, and drill mounting holes. Bend tubing for bull bar and cut tubing for cross bar. If a skid plate is required in the design, cut that to shape.

Check parts for proper fit. Weld tubing and brackets.

Apply the desired finish to the bull bar. Aluminum can be anodized, giving the bull bar assembly a durable finish. Steel can be chrome plated or painted.

Verify location of holes for bull bar on underframe. Once satisfied with location, drill holes.

Mount bull bar to underframe. Tighten nuts and bolts securely.

Items you will need

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