Its been a while since I returned from another successful trip across the WA deserts and have time to write up some of the stuff I did before heading off.
Needed to attend to the spotlight mounting on the bar as the lights kept moving, removed the lights and tapped the bar flat, sanded the remaining powder coating off to give the lights a flat surface to sit on and found this --
a series 0f cracks around the OD of the washers caused by the bar being too light duty and the lights vibrating. The whole deck of the bar was cracked so I made up a couple of 3mm plates that picked up all the bolt holes and laminated the deck of the bar between them with Sikaflex - thats that problem solved.
The powder coating inside the bar came off in big sheets so was fairly easy to get a good contact with he bar.
Fitted a set of DRL's and a mount for the Gopro, gives a great view
Removed and straightened the bash plate and found some cracks around the rear mounting points so cut and welded a strengthening plate over the damaged area and fabricated a hump to accommodate the diff drop.
The hump took a few hits and has a fair bit of 'rock rash' as I learnt exactly where it was and can mostly navigate across obstacles now and miss it.
I also modified my canopy and removed the troublesome zippers from the back panel and build a new camper insert, thats another story and I'll write it up when I have time.
The above mods were all well tested across a trip made up of 12000km of bitumen and 7000km of dirt roads and tracks and performed perfectly, it was my first trip without bull bar problems so can recommend any of the mods I've made.
Geoff