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jevermeister

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Discussion starter · #1 ·
Hi,
today I tried to isntall a rollbar onto my D40 DoubleCab but noticed that the hole I had to drill will be on top of the fixation point of the rail system, in order to mount the roll bar I have to move the bar either 5cm back or forward, 5cm back woul lock very bad and 5cm forward would leed to a gap of 1cm between cabin and rollbar.

will 1cm be enough or will the cabin touch the rollbar?

Thanks for you help in advance.

Nils
 
Re: How much space between Rollbar and Canin

jevermeister said:
Hi,
today I tried to isntall a rollbar onto my D40 DoubleCab but noticed that the hole I had to drill will be on top of the fixation point of the rail system, in order to mount the roll bar I have to move the bar either 5cm back or forward, 5cm back woul lock very bad and 5cm forward would leed to a gap of 1cm between cabin and rollbar.

will 1cm be enough or will the cabin touch the rollbar?

Thanks for you help in advance.

Nils

1cm/10mm is not enough clearance, the bed and cab of the Navara will flex and move, especially over rough or uneven surfaces, more so if the bed is loaded. Then you'll end up with a dent or two at the cab rear.

I know of at least two people now that have fitted the bars to close to the cab, and suffered dents as a consequence.

Set the bar a minimum of 25mm away from cab, this will also make cleaning much easier :wink:
 
Re: How much space between Rollbar and Canin

Lil trucker, you seem like a man in the know and I need some technical guidance regarding a rollbar currently sitting on my roll n lock (not ideal). I'm unable to PM though...
 
Re: How much space between Rollbar and Canin

Hi mate, the way i did mine:

I bought a Roll N Lock cover, i fitted the cover, and then marked out where i wanted the roll bar to sit on top of the cover.

I drilled the cover rails, and fitted riv nuts into the holes, the position of the holes is critical. They need to be in a position that won't hinder the operating of the cover, also far enough over to miss the top of the truck bed.

I did this as i didn't want to drill bolt holes in the truck, and so my roll bar would bolt to the top of the cover, and not the truck.

So, you mark the four bolt holes on the cover, drill them and fit riv nuts, then bolt with stainless bolts into the riv nuts.

Then you will need to cut out the front corners of the roller cannister lid. This will then fit around the front section of roll bar. I also made some rubbers seals to go around the cut outs.

This is a good set up for me, as i often have to remove the roll bar to tow my fifth wheel trailer. The roll bar can be removed very quickly.

I'll see if i can find any pics :thumbright:
 
Re: How much space between Rollbar and Canin

just done a search for the fitting of mine and it shows up on the search but on clicking says does not exist, so guessing more site issues?




not sure if this helps without photos...



I have the Armadillo roll top fitted with a 2 / 3 bars / roll bar from auto styling, because the bar is only cosmetic and comes in sections I was able to be creative and modify it as required for fitting with the roll top.

Because each of the roll sections comes in three section / parts, I was able to shorten the end sections (part no’s AS/1 and PS/1/DX) where they join to the centre section and re drill the connecting bolt holes. This is quite straight forward, but a lot of care must be taken not to mark the bars. I found the easiest and best way (IMO) was to mark the bolt holes prior to any cutting to allow for correct alignment when cut.
(If you use the same bar as mine you will end up with making 6 cuts). If I remember correctly I took about 20 to 30mm off each one, but please double check this!

I drilled 4 holes in the Roll top cover to allow the front 2 bars to bolt directly to it, this means mounting the bars to the cover before fitting the roller cover.

For the final bar, this is a little more involved, because the front two bars are now sitting that little bit higher, I had to make some spacers / feet for the rear bar the same height as the roller cover / lid, I then cut the side sections off the mounting bracket supplied with the bar (creating an almost round plate) and welded these in to the centre of the spacers. Then I drilled 2 holes (about 6mm – if I remember correctly but to suit 10mm headed bolts) in each of the mounting brackets opposite of each other, then I drilled 2 more in each side of the roll top side runners (making sure they did not interfere with the sliding mechanisms / operation. Then using about 50mm? Long 10mm (headed) bolts I welded them into the spacer brackets facing down. (yes the OME brackets are sided – counter sunk) after checking the spacers fitted on to the sides of the roller shutter and the bolts went through ok I bolted the spacers to the legs of the roll bar, using the supplied counter sunk screws.

The complete front part of the bars can now be put in place (good idea for some help at this point) with the bar clamps fitted loosely to enable you to locate and hold the rear until located and secured fully. Then lifting the finally bar on again with some help locate the 4 holes (2 each side) and insert your spacer mounting bolts, then the top of the bar in to its bracket on the first bars. Fit some washers and nuts on the 4 bolts, tighten the clamps across the top of all the bars, and fit the 2 Philips screws in to the roller shutter cover and job done.

I have had mine on for nearly two years now you can shake the truck with out any problem or movement of the bolts/s screws; periodically I tighten the 2 Philips screws. But that’s all, and if I was to ever remover the roll bars I would only have 8 holes 4 of which are only about 6mm and 4 that are about 10mm. The 4 small ones could easily be covered up and at worst the roller cover replaced to loose the 10mm one.

I hope this is of some help, feel free to ask any further questions, and good luck with your install, and in mine opinion its worth the trouble..
 
Re: How much space between Rollbar and Canin

Lil'Trucker! said:
Hi mate, the way i did mine:

I bought a Roll N Lock cover, i fitted the cover, and then marked out where i wanted the roll bar to sit on top of the cover.

I drilled the cover rails, and fitted riv nuts into the holes, the position of the holes is critical. They need to be in a position that won't hinder the operating of the cover, also far enough over to miss the top of the truck bed.

I did this as i didn't want to drill bolt holes in the truck, and so my roll bar would bolt to the top of the cover, and not the truck.

So, you mark the four bolt holes on the cover, drill them and fit riv nuts, then bolt with stainless bolts into the riv nuts.

Then you will need to cut out the front corners of the roller cannister lid. This will then fit around the front section of roll bar. I also made some rubbers seals to go around the cut outs.

This is a good set up for me, as i often have to remove the roll bar to tow my fifth wheel trailer. The roll bar can be removed very quickly.

I'll see if i can find any pics :thumbright:
Ok thanks. The rails I have (the ones with the 'Navara' plates...the rear part sits awkwardly so the current position of where the hole would be isn't ideal. Don't suppose you could advise by email if I were to send photos? Pulling what's left of my hair out trying to come up with a method to secure the rear bars rather than have them sat awkwardly on bits of rubber.

Cheers
 
Re: How much space between Rollbar and Canin

Ok. No problem. Images attached. Would be great to get some advice on how to sort this. I bought it all second hand so the bad cut on the Roll n Lock cassette was somebody else. I'm hoping to buy a new cassette lid and do a better job.
 

Attachments

Re: How much space between Rollbar and Canin

shyman said:
Ok. No problem. Images attached. Would be great to get some advice on how to sort this. I bought it all second hand so the bad cut on the Roll n Lock cassette was somebody else. I'm hoping to buy a new cassette lid and do a better job.
The rear of your roll bar has different mounts than mine, mine has flat plates like the front section. So from looking at the pics, i guess you're limited as to where the fixings can go :(

The cannister lid can be replaced and cut a bit more tidy, so that should be ok.
 
Re: How much space between Rollbar and Canin

shyman said:
Anyone? Pllllease
Hi mate, have a look at this thread, it will give you the idea of how i did mine:

viewtopic.php?f=43&t=27804&p=262353&hilit=Fitting+roll+bar+with+roll+n+lock#p262353

Looking at your roll bar, i think it will be tricky, so i think you'll either need a different roll bar or, you need to fit stainless plates to the underneath the bars, so that you can drill the holes further over.

Even grind the existing plates off would look better.

Steve :thumbright:
 
Re: How much space between Rollbar and Canin

Thanks Steve, tremendous idea...any idea what's holding the rear Rivnut? I have rubber gasket material I could wedge under the 'space' then could fill with black silicone.

So I'm thinking now all I need is a new cassette top (rip off) and to drill new holes to the inside of the rear plates.

Thoughts?

What size fasteners did you use?

No idea how to use Rivnuts so better get myself taught!!
 
Re: How much space between Rollbar and Canin

Hi mate, the Riv Nuts compress slightly to hold them in place, you need a tool to apply them, or can make one from a long bolt or some studding that has the same thread as whatever bolts size you'll be using and a couple of nuts. The ones i used take an M6 thread, i used stainless bolts.

I then used larger bolt cap nuts as you can see in the other thread to cover the original fixing holes in the rear bar.

looking at your roll bar, i can't see that you'd get the new fixing holes over enough on the roll n lock rails?

My roll bar is fixed to the roll n lock rails in a position between the bed of the truck, and away from the channel that the shutter slides in. Obviously this is so the operation of the shutter isn't effected, and no holes in the truck.

It sounds a bit complicated but, quite easy to mark out. The way i did mine was to remove one of the rear caps from the roll n lock rails, you can then see all the profile and channel etc, make a not of the dimensions where you can drill without hindering the operating.

Make sure the roll n lock is in the right position on the truck, and is not going to let in water at the front, and all is working ok.
Place the front section of bar on first, make sure it's square, mark the holes in the cannister housing, remove the bar, drill the cannister, fit the riv nuts, then bolt the front roll bar back on.

Now fit the rear section of roll bar to the front section, using the dimensions found earlier when looking at the rail profile, mark the fixing point on your rear roll bar, remove the rear roll bar, drill the marked holes, re-fit the rear bar, now mark the holes onto the roll n lock rails.

Remove the bar, drill roll n lock rails, fit the riv nuts, now re-fit the rear bar, and fix down into the riv nuts, tighten all fixings, and that's it, re-fit the cannister lid, or get a new one and re-cut it.

I have to remove my bar when towing my fifth wheel, this set up allows me to remove or replace the roll bar very easily. I have even now made up some covers, so that when the roll bar is off, the cut outs in the cannister lid are covered.

Anyway, hope this makes sense?

Steve
Image
 
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