AMI Swing Step Bull Bar WILL FIT your GEN 4 Express/Sport

[GIJoe2010]

Time to paint brackets and contact points on bull bar. The powder coating on the bar is very thin, the slightest rub can and may leave a mark.

More to follow . . .

 

[GIJoe2010]

No real progress today due to a long day at work and daylight savings time, but thanks to @JB1 for the tow hook mounts. They’ll come in handy in an attempt to retain the OEM tow hooks with the bull bar. Again, as previously mentioned, if they won’t work out they’ll be a good starting point for a template.

I’ll RTS them back to @JB1 if I can’t use them, thanks again brother.

 

[GIJoe2010]

Did a test fit and these fit perfect in the OEM location, however, due to my mounting of the bull bar they won’t work in the OEM spot. I tried to move them to the front of the bumper mount but the holes are not high enough.

I created my own set based off of these in 2” angle iron but I don’t have enough purchase on the outer most side (on the left side), however, I was able to install them and adjust them on the front of the mount and with no issues save for the outer portion.

I need some 3” angle iron and I’m set.

 

[GIJoe2010]

And another for reference

 

[GIJoe2010]

The height of the holes difference between homemade and @JB1 mounts. His are too low.

Again, with some 3” angle, this will work perfect. Once I’m done with mock-ups and such, you can have these back @JB1, thanks for your help

 

[JB1]

Your doing a fine job

 

[GIJoe2010]

Thanks.

Any thoughts on where I can get any 3” angle iron?

Unfortunately, neither the local Lowe’s or Home Depot have anything larger than. 2” angle iron.

 

[GIJoe2010]

Found it. 5 feet of 3” angle iron (3/16” thick) for $20 at a local metal supply shop. This is perfect for what we’ll need. Looks like I have enough for at least 3 sets of tow hook (relocation) brackets.

Once the weather subsides a bit I can get to measuring and cutting.

 

[JB1]

That’s great

 

[GIJoe2010]

So based off @JB1 custom mounting brackets I created my own in 3” angle iron.

 

[GIJoe2010]

And then, there’s a specific order in which to attach it all. First, the bull bar brackets aligned on their holes. Then the tow hook relocation brackets. Then the tow hooks to the tow hook brackets and on the frame horn. Until you get it all on and snug. With my tow hook relocation brackets, the tow hooks are easily 2” away from the bull bar brackets so there should be no issue with attaching recovery cable or rope.

 

[GIJoe2010]

Then taking the previously made channel steel brackets you attach using your acquired stainless 8.8 bolts/washers/nylock nuts (Lowe’s or Home Depot). It’s set on at the lowest setting in the slots, but still sits high enough on the bumper. After simply snugging everything evenly on both sides, dont know the lb/ft on the 4 attachment bolts; but I found 4 threads shown on each, and there was just starting to show so deflection in the channel brackets. As you can see the bull bar is level. I won’t be using it as a step stool to get into the engine bay very often but even after hacking up the original bull bar brackets it can handle my 200 lbs.

 

[GIJoe2010]

I will be adding more pics and such as I make any amendments or have any ideas. I still need to paint my tow hook relocation brackets as well.

Please ask any questions you like and I’ll elaborate further.

 

[JB1]

Wow that’s awesome, nice job

 

[GIJoe2010]

Thanks @JB1 those brackets you let me use were instrumental in making my set in order to use my tow hooks with this bull bar. I’ll be getting them back to you in the next few weeks.

Next project . . .

 

[huntergreen]

Does the step rattle on uneven roads ? thanks

 

[GIJoe2010]

@huntergreen I haven’t heard any new rattles from the truck since I installed it this afternoon from just driving around town. I’ll recheck it this thanksgiving weekend and see what needs to be tightened . . . even though I’m going to take it all apart again to paint the tow hook relocation brackets and touch up a couple other things.

I too have heard of some that have this bull bar and have rattles and it comes from the Swing Step itself needing a second latch. I’m going to reach out to AMI about getting another (the passenger side) latch for peace of mind.

 

[AdamKan]

@huntergreen I haven’t heard any new rattles from the truck since I installed it this afternoon from just driving around town. I’ll recheck it this thanksgiving weekend and see what needs to be tightened . . . even though I’m going to take it all apart again to paint the tow hook relocation brackets and touch up a couple other things.

I too have heard of some that have this bull bar and have rattles and it comes from the Swing Step itself needing a second latch. I’m going to reach out to AMI about getting another (the passenger side) latch for peace of mind.

Yours only has a latch on one side? I just installed mine from American trucks and it has a latch on each side. No rattling at all

 

[GIJoe2010]

@AdamKan Yup, just driver’s side (best seen in post 35).

I’ll definitely get in touch with AMI for the passenger side latch, as well as inform them that with some tweaks to the bull bar brackets and creative cutting on the lower bumper filler valance these bull bars can fit Express and Sport models (with the plastic bumpers).

 

[GIJoe2010]

As a side note: when looking at the bar from the side, there is space between the two mounting bolts on each side to drill an additional “guide/alignment” hole. The spot in mind actually falls into the precut swing step bar slot (as manufactured).

It would lend additional rigidity as there is a 3rd mount hole as well as it would align the mount and bar at a single point if you had to take it on or off for maintenance or repaint.

I will caveat this in that it could make it a permanent setting, but I’m sure I could make longer brackets (see post 32 for bracket reference) to allow for varying alignment holes in different locations, in order to preset it on the bull bar brackets as high or low as I like.