Brush Bar Installation-Help

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Author Message   Steve Fesperman Posted on Thursday, October 17, 2002 - 09:30 am:    I need some help with the installation of a brush bar on a 2000 DII. It looks like there will be some cuting of the bumper (not excited about that). What is the best tool to use or alternatives? Do I have to take the bumper off? Will I have to drill holes to mount? Etc. If anyone has pictures or instructions from a unit they purchased that would be great. If not, I would appreciate any assistance. Hopefully, I plan on doing this in my garage and avoid going to a shop. Thanks in advance---Steve   Ed Petrush (Exp3) Posted on Thursday, October 17, 2002 - 09:38 am:    Need more details.. what type of brush bar (did it not come with directions??) Manufacture & model... Usually these are direct bolt-ons..   steve Fesperman Posted on Thursday, October 17, 2002 - 09:46 am:    Factory (Genuine) Brush Bar with the headlight guards. Unforntunately, I jumped the gun and purchased it (used) before looking into the details. The bolts are included, but no directions. I assumed that it would bolt on by passing up under the bumper, but last night I realized that was not the case.   Dave Smith (Javelinadave) Posted on Thursday, October 17, 2002 - 10:00 am:    Pretty tough job without the instructions. As with every other part on your Disco, there is the easy way, the hard way, and the Rover way. See if your dealership has a copy of the instructions laying around. As for the cutting, I drilled a hole in each corner of where the cuts needed to be made. I then used an electric jig saw with a fine blade to make the cuts. Good luck.....Dave   George Clayton (Offcamber) Posted on Thursday, October 17, 2002 - 10:57 am:    EEK!....cutting to get your stock guard on? Are you sure you bought a D2 guard, and not a D1? I just removed my factory guard, and installed an ARB. The easiest way I found, was to remove the stock bumper. That said, and if you don't want to, there were basically 6 attachment points. 4 on the frame horns (2 bolts per side), and one on each side of the front fenders where the bumper mounts to the fender inside each wheel well. You will definitely want to remove the wheel wells and lower grille assembly (right term?) for easier access to the frame horns and inner fender. First thing to do will be to attach the small metal tabs in between the stock bumper and the fender (best done with the tabs removed from the guard) piggy-backing off the attachment points there. Sort of a bolt-sandwich with rubber grommets separating the mess. With that done, you should be able to loosely bolt the guard to the frame horns, check for balancing and spacing, and tighten accordingly. Certainly a shade-tree approach, as I didn't have the install instructions available, but feel free to email me for specific questions....I'll try to help as I can.   Steve Fesperman Posted on Thursday, October 17, 2002 - 12:15 pm:    I am positive it is for the DII. Does anyone know if there are different version of the DII bumper assembly or do all have to be modified to install the brush bars? Looking under the vehicle, it is hard to tell where it bolts to. So far I can't find any pre-drilled holes that look like they would accept the bar. And to my limited knowledge, the brush bar only has four bolts to hold it on (2 on each side). As far as cutting the bumper assembly, there is a removable door but it is only on the drivers side. Is that where the bar attaches? I am going to stop at the local dealer to look at other DII's on the lot and I will ask about directions. Thanks so far.   Willard Lee (Wlee69) Posted on Thursday, October 17, 2002 - 05:48 pm:    I just installed a factory DII brush bar a couple months ago....you do need to take the bumper cover off and you also need the directions (there is a template you cut out of the directions to guide you in the bumper cutting. I used a dremel to do the cutting. The whole job is a total PITA - just see how much the dealer is asking for the installation!!!! The mounting points are so close the the bumper cover, you pretty much need to take it off to do the install. I also recommend another person to help you hold it in place (the grill) while you tighten everyhing up! If you need to directions, I can search to see if I still have them - the only thing that will be missing is the template for the cutting!!! Hope this helps....and let me know if you need help!   Willard Lee (Wlee69) Posted on Thursday, October 17, 2002 - 06:12 pm:    I found the manual and scanned it in for you into a PDF file. The last page is sorta messed up because I cut the template out from the other side! Good luck Will http://home.earthlink.net/~wlee69/images/manual.pdf   Steve Fesperman Posted on Sunday, October 20, 2002 - 12:15 pm:    Thanks for the directions. I bought the necessary parts and will install next week. --Steve