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PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class DIY Forum : Budget Rocker Panel Protection/Sliders

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Budget Rocker Panel Protection/Sliders
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Posted 11/27/2012 9:39 PM
csc
Member


Date registered: Dec 2011
Location: Charleston, SC
Vehicle(s): 2014 G 550
Posts: 17

Budget Rocker Panel Protection/Sliders

Phase 2 of off road prep for the G is in full swing. Rocker panel protection for under $200, so far. I'll only post a few shots. If anyone is interested, I can post more.

I purchased 2"x4"x3/16" steel (Square) tube from the local steel yard.

The Build:
1. Remove side steps from the G, but leave the mounting brackets.
2. Trim the brackets with a cutting wheel to the interior width of the steel.
3. Measure and cut the steel tube the length of the slider
4. Line up the slider with the brackets and mark
5. Cut holes in the side of the tube to allow the brackets to slide in.
6. Mark the bottom of the tube for the bolts and drill
7. Install bolts on the brackets (I had to trim the bolts to get them to fit inside the tube
8. Slide tube over brackets to check fit. This will require moving bolts around, banging, etc.
9. Once things line up, remove the slider and paint.
10. Reinstall slider on bracket. Have a helper lift up on the slider so the bolts poke through and install lock nuts.
11. Drink a UFO (Weiss beer)!
12. Repeat on other side!

This was a pretty involved project. Total cost $130 Steel, $30 SSteel Bolts, $15 Paint, $20 cutting blades Total about $200 bucks.

They turned out to be even stronger than I expected. I'm going to cut a couple of holes in them to accept the high lift jack. I wouldn't jack it on a regular basis, but in a pinch, I'm confident it will hold.

Planning a trip to the Gulches Off Road Park in January to try out the new additions. Will report on durability. We'll see if I lose a couple of bolts on rocks.

Cheers,

Chad






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#209228
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Author
Posted 11/28/2012 10:52 AM
drey
Extreme Veteran


Date registered: Sep 2012
Location: Scottsdale AZ
Vehicle(s): 04 G500
Posts: 364
300
Re: Budget Rocker Panel Protection/Sliders

couple issues I see.

Your frame and exhaust will hit first.

If your sliders do hit the bolt heads will be mangled and you will hang up on them.

Round tube is typically used because no matter the angle of hit the contact patch is minimized, less friction.

You can solve the bolt head issue...

look through the mcmaster carr on line fastener catalog and pick some low profile pan head cap screws. Counter sink them. Or get the sliders welded to the brackets that is probably the strongest way.

Fixing the rest would require a re do.

#209246 - in reply to #209228
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Author
Posted 11/30/2012 3:03 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: Budget Rocker Panel Protection/Sliders

Welding would be good.  

Don't worry about hitting the frame.  That is one of the best parts of the G ... it slides very nicely on the frame.  

You can protect the mufflers by welding on little ramps front and back. 

#209328 - in reply to #209228
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Author
Posted 11/30/2012 6:08 PM
csc
Member


Date registered: Dec 2011
Location: Charleston, SC
Vehicle(s): 2014 G 550
Posts: 17

RE: Budget Rocker Panel Protection/Sliders

I have no worries about the frame or the square shape. I had square sliders on a TLC and a Disco with no issues. The mufflers are exposed and the only way to deal with it is some kind of skid plating.

There really isn't a good way to weld since the brackets are inside the tube. I would have to cut much larger holes in the side of the tube to get the stick in there or cut holes in the top, which I have been avoiding, but it is causing the grief with the bolts on the bottom.

I'll see how the perform and adjust as needed.

Thanks for the comments. Drey, I am looking into some interesting low profile fasteners.
#209331 - in reply to #209228
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Author
Posted 11/30/2012 6:57 PM
drey
Extreme Veteran


Date registered: Sep 2012
Location: Scottsdale AZ
Vehicle(s): 04 G500
Posts: 364
300
Re: Budget Rocker Panel Protection/Sliders

Oh I could weld them.

Roll through AZ. :D
#209336 - in reply to #209228
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Author
Posted 11/30/2012 7:03 PM
stevegsmith
Expert




Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: Budget Rocker Panel Protection/Sliders

Why not drill holes in the top of the tube so you can plug-weld to the bracket? Grind back flat and paint.
#209338 - in reply to #209228
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