Cross Section/Innards of Factory Step Bar

[OffTrac]

Does anybody know how the inside of the factory step bars are constructed? Extra love for anyone who has a picture of a cross section of them.

 

[WidgetTrac]

I.ve got one apart now - which part are you interested in?

 

[snoranger]

The pair I took of my '01 parts truck were constructed of rust and little bits of what was once metal.

 

[OffTrac]

Well, I guess I can only answer that by spilling my dumb idea. I'm considering building sliders with the step bar overlayed on the step part. So, basically I'd be cutting into the bottom to attach the step to the steel step part. May be a crazy idea and not quite work like I'm thinking but I'm still in the planning stage.

If you have anything that would help along those goals, I'd greatly appreciate it. I just want to know if I'm going to destroy them if I cut into the bottom to attach it to the steel. If so, and this won't work, I'd rather just give them to someone who wants them as I know people are always looking for them.

 

[colintrax]

I was planning on kinda doing the same thing, you have a problem though. The step bars attach to the body (not good for rock sliders) and the rock sliders attach at the frame. So you would have to cut any part of the steps that get close to the body or expect some body damage/rubbing when you hit the trails and start flexing the frame/body.

 

[OffTrac]

I planned on making sliders like everyone else here has done. They will attach to the frame, bolt-on. I'll remove the brackets from the factory steps and only have the step bar left. I would cut down the length of it to overlay on the steel slider. Basically, the stock step bar would become a plastic step pad overlay on the steel sliders, if that makes sense.

 

[colintrax]

Ok, so I guess these are actually step bars. The running boards on my x wouldn't work, and I'm not a fan of the bars.
Don't see why this wouldn't work, regardless of whats inside the bars you could always machine out the inside. At my school we have a big, facing mill that would work. Are you going to use the bends at the end or cut those off and leave it a straight section? If you do the bends, then a cnc mill would be needed and that's gonna be $$ or you could just use a manual mill and have the straight section done and spend lots of time with a dremel (not gonna fit great though)

 

[OffTrac]

regardless of whats inside the bars you could always machine out the inside.

That's why I'm asking. As light as they are, I assume they're just a hollow tube. I'm not going through that much trouble to do this but if I can just cut a section out of the bottom and rest the steel tube inside of it with flat stock attached at the bottom for fastening the factory step onto it, I'll give it a go. If it's much more than that and requires more than what I have on hand, I'm sure I'll just scrap the idea.

Haven't put much thought into the bend at the ends. Figured they could either be incorporated if easy or cut off if a hassle.

 

[colintrax]

I think we're thinking of 2 diffrent ways of doing this. In my head, it wouldn't matter if it is a hollow tube, just use the same diameter tube (or close) for the sliders. If it has something inside of it (I would assume it has some kind of support in there) then use flat stock, and machine the inside/outside to the size you want and set it on there.

 

[OffTrac]

If it has something inside of it (I would assume it has some kind of support in there) then use flat stock, and machine the inside/outside to the size you want and set it on there.

That had crossed my mind. Not sure how to securely fasten it on there without knowing how the inside is constructed, though. Or am I misunderstanding something?

Here's a picture of what I'm working with for reference. I want it to sit at about the same level. Basically, I want the same look, but I want these to be sliders instead of rocker panel crushers.

 

[01STrunner]

Not 100% sure but I really think the inside of the tubes is hollow minus a couple supports here and there because when I was moving them around off the truck I could hear dirt and other crap falling from one end to the other.

 

[WidgetTrac]

Okay, I never pried hard enough to break or pull off the step inlay, but there is a channel running down the length of the top of the main bar, under the plastic tread inlay. The end "horns" have short metal supports inside:

The support is bolted thru the plastic - I unbolted it and put it back on:

The supports are attached to studs that are part of an internal bracket that fits inside the ends of the bars... I _assume_ that if the tack welds were ground out you could remove the internal brackets and see all the way thru the other end. I was thinking if deleting the horns from mine, in which case I'd be opening them up like that and could post pix, or you could figure out how to pry off the step inlay and see thru holes what they used for the 6 female threaded bosses on the bottom where the brackets attach.

 

[WidgetTrac]

Yeah, I think they are a continuous tube, sta mped down into an oval with a flat face and center channel. You could probably cut away the whole bottom half, bolt thru the center groove to bolt it onto the slider, then pop the inlay back in and the upper side would still be stock looking and reasonably stiff due to the channel shape, or so it seems to me.

 

[OffTrac]

Perfect. That is exactly what I was looking for and hoping for. I assumed its a tube as you pointed out, maybe with a few supports in a couple places. This seems very doable. Now, if I can just find the time. Body bushings are first priority and I haven't even been able to get to them.

 

[LONO100]

hey trac, mine look a little different from those in the last pics. ill take a few shots and post it as soon as i get a chance.

 

[WidgetTrac]

The tread inlay comes out eazily enough - the center channel goes down almost half way, so you could cut a set of slots in the _side_ of the bar, stick the ends of the brackets (with threads tapped) in thru the slots, and bolt together inside the channel. Then replace the inlay and the bar is both slider and step in one.

Once you take both the curved ends off, there are some peek holes you can see inside. Mine have a welded seam running straight down middle of the bottom side, right through 3 of the bolt bosses (which I believe are installed from inside, and maybe friction-welded in place.

 

[WidgetTrac]

Couple more pix...

After stripping it down, it's easy to see inside - nothing in there except the 6 nut-serts and the studded plug pieces at each end.

 

[OffTrac]

Lono, I'd like to see what yours look like if it's not too much trouble. Mine look exactly like Widgets as far as I can tell, though. They may have changed from '01 to '03 at some point. Still interested to see yours, though.

Widget, thanks a ton. Your info has been very helpful.

 

[WidgetTrac]

Hugh, no problem, your pics have been a huge help to me!


Lono, my trac was in the 1st batch that came to Houston in 03/2000 so it may have a few differences even from the fall '00 batch. If there are different kinds out there, I'd like to see them too!

Right now i'm lifting the OEM bars 1.5" via bracket trim & redrill, which requires the curves to come off the ends. The little round caps can come off the curved sections and be put directly on the bars, which gave me an idea...

By attaching the 4 curved sections together you can make a circle - or - a wavy bar. So... What i.m thinking is to got a bunch more of the curved sections and make WAVY STEP BARS, and not only that, but they shall be painted. Painted like Snakes!!! Yesss! You heard it here 1st - wavy painted snake bars!!! They'll be all the rage in Paris next spring... On the French monster trucks. Maybe not. Forget it.

 

[theluke19]

By attaching the 4 curved sections together you can make a circle - or - a wavy bar. So... What i.m thinking is to got a bunch more of the curved sections and make WAVY STEP BARS, and not only that, but they shall be painted. Painted like Snakes!!! Yesss! You heard it here 1st - wavy painted snake bars!!! They'll be all the rage in Paris next spring... On the French monster trucks. Maybe not. Forget it.

Epic mind loss!!!