Custom Nerf Bars

Here's how I made these;  (Any questions email me)

you will need:    4 - 1 1/4" x 3" x 1/4" steel tubing - for the 45 deg ends

                        4 - 3/4" x 6" x 3/16" steel tubing - for the cross bracing

                        2 - 1" x 16" x 3/16" steel tubing - for the outer nerf bar

                        2 - 1" x 11 1/2" x 3/16" steel tubing - for the front support bar

                        2 - 1" x 12 1/2" x 3/16" steel tubing - for the rear support bar

                        8 - 3/4" x 7/8" x 3/16" steel tubing - for the bolt hole reinforcement

                        4 - 2" grade 8 steel bolts for the outer bolt points (only use grade 8 anything lower I've broken!)

                        4 - 1 1/2" grade 8 steel bolts for the inter bolt points  (only use grade 8 anything lower I've broken!)

                        12 - grade 8 anti-vibration nuts and washers  (only use grade 8 anything lower I've broken!)

1.  Weld the 1 1/4" tubing at a 45deg angle to the 16" tube.

2.  Weld the 11 1/2" and 12 1/2" tubes to the 16" tube centered using the 3/4" x 6" tubes as the cross support, one in the front and one about 2" to 3" above the end.

3.  Using clamps, mark the holes for drilling, by removing the floor boards and marking the existing holes, and drill.

4.  Insert the 3/4" x 7/8" tubing pieces down the 11 1/2" and 12 1/2" tubes so they are centered in the hole, these supply support so you don't crush the main support tubes at the bolting points, weld them in place if you can.

5.  Now use the 2" bolts with a nut as spacer in the outer holes and bolt to the ATV.

6.  I painted my with primer and black high gloss.

Mine are flush in the front with a 1" drop off the fender and slightly out from the end with a 2 1/2" drop off the fender.  I'm not the greatest welder ... but my welds haven't broken on my yet.  :)   I have about $40 in steel, bolts, and paint on this project.