As the popularity of off-road and sport-utility vehicles has soared, so have their sticker prices. There's little doubt that many owners are hesitant to take their off-road vehicle off-road once they consider that the price they paid for it is not far below what they might have shelled out for a luxury coupe or a sports exotic. One thing that may bolster the confidence of the reluctant off-roader is the installation of a grill guard to protect the front end of the vehicle. Though this bolt-on accessory, and accompanying brush-guards, will offer you no protection against getting stuck or lost in the wilderness, at least your front-end paint job will remain relatively intact when you have to negotiate a thicket of sumac. One thing is certain: a grill guard does take any outdoorsy-looking vehicle a step up in terms of rugged appearance. The newly accesorized land cruiser will be something that Rambo would be proud to be seen driving. Kidding aside, these add-ons serve a practical function if you do intend to veer off the asphalt, and as a bonus, they serve as a solid mounting-support for a winch -- something no serious off-road explorer would ever want to be without. In terms of appearance, these are typically available in black or chrome finishes, or in a powder-black that's more resistant to rust. The installation is fairly straightforward. Make certain that the guard you select is compatible with your vehicle and your intended usage. Some come preassembled to bolt on more or less as a single unit, but the one we installed on our sample vehicle (a 2000-model Ford F150) comes as a modular kit with several pieces (figure A). This leaves more leeway for adjustment and offers more flexibility for modification or subsequent add-ons such as off-road lights. The kit we installed was designed specifically to fit our make and class of vehicle. The brush guards are an easy addition. They simply bolt onto the vertical members of the grill guard and are positioned so they protect the headlights (figure B ). For ease of installation and better viewing, our installation was done with the vehicle on a lift. The installation can also be done using an under-car jack and jack-stands. Be sure to chock the front wheels for added safety. Materials: Grill-guard and brush-guard kit including installation hardware
Socket-wrench set
Electric drill
Electric cutting tool or small saw
Silicone sealer
Safety glasses - Since this project will involve some work with electrical wiring (disconnecting the bumper lights), disconnect the negative battery cable before you begin work.
- The grill guard is attached to the vehicle by means of frame-extenders that bolt on to the frame. Installation will require first removing the bumper, which in this case is held on by two bolts. Disconnect the bumper lights before you lower the bumper. You'll also need to temporarily remove the tow-hooks, also held in place by bolts.
Important: Take note of the factory alignment of the bumper before you remove it. You'll be duplicating the original alignment when you reinstall. Take special note of the spacing between the top of the bumper and the bottom of the grill and headlight-mounts. With the bumper removed, the extenders insert into the openings in the end of the frame and are bolted in. Loosely install the rear bolt that holds the extender in place. Before you tighten it all the way, however, slide the tow hook in place (figure C). You can then loosely install the bolts to hold both the tow hook and the extender in place (figure D). Before tightening down the bolts completely, make certain that the frame extensions are centered. According to the manufacturer of these guards, a distance of 31-1/2" from one extension to the other will ensure proper centering. Once you've checked the centering, tighten down the bolts securely. Once the extenders are attached to the frame and properly spaced, you'll need to cut openings in the bumper. Two openings are cut in the lower plastic portion of the bumper for the insertion of the extenders. Two others will be cut in the upper portion of the bumper for securing upper mounting brackets that come with the kit. (These replace the existing factory mounting brackets that hold the bumper secure.) The manufacturer supplies diagrams showing the locations where you'll cut the openings, but it's still advisable to hold the bumper up to the extenders to double-check the locations. Mark the locations, then cut the openings (figure E) with an electric cutting tool (e.g., a Dremel tool) or small saw blade. Once the holes have been cut, install the new upper mounting brackets according to the manufacturer's instructions. With the frame extenders and new upper mounting brackets installed, reinstall the bumper. Take care to line the bumper up precisely since the alignment of the grill guard will be based on the bumper's alignment. The extenders should fit properly through the holes you cut in the bumper (figure F) Once the bumper has been attached, plug the bumper lights in. With the bumper reinstalled, and the frame extenders and the upper mounting-brackets all installed, you can begin a rough assembly of the grill guard (figure G). Follow the kit instructions to install the side members to the upper brackets, and then install the cross members (the upper tube and the lower winch-mounting plate) between the side members. Put all the parts in place, but assemble them loosely. You'll need some maneuverability to make final adjustments before tightening everything down. The next step involves some drilling through metal. The bottom of the side mounts do not have predrilled holes (for attaching to the frame extenders) like the rest of the assembly since exact placement for these may vary slightly between vehicles. You'll need to adjust the fit of the side members and check the alignment and clearance of the components in relation to the bumper. (This kit includes shim plates that, if needed, will help the side members and frame extenders fit exactly.) Once you have the proper alignment and clearance, clamp the side member to the frame extender and, using the frame extender as a template, drill holes in the side member to match the ones in the extender (figure H). Do this step on both sides. Safety tip: Always wear safety goggles when drilling metal. Insert the bolts to attach the lower portion of the side member to the frame extender, then install the lock-washers and nuts (figure I) and tighten securely. Tip: Use silicone to coat and seal the newly drilled holes and the base of the bolts in order to prevent rust. Tighten up the entire assembly securely. Follow the manufacturer's instructions to attach diagonal braces that support the lower cross member (the winch-mounting plate) by attaching it to the frame. With the grill guard installed, mounting the brush guards is fairly simple. These require no drilling and simply bolt on to the side members. Nylon washers serve as spacers between the side member and the base end of the brush guard. Adjust the outer ends of the guards for best alignment with the lights, and so they don't scratch the painted surface, then tighten the bolts securely. Place the plastic inserts (included with the kit) in any unused holes in the assembly.
RESOURCES :
Vehicles provided by McNelly-Whaley Ford Lincoln Mercury
750 Dolly Parton Parkway
Sevierville, TN 37862
Phone: 865-453-2833
Web site: www.ford4u.com
Warn Industries
Offroad accessories shown in this segment are from
Warn Industries
12900 S.E. Capps Road
Clackamas, OR 97015
Toll-free: 800-543-9276
Web site: www.warn.com
The Off-Road 4-Wheel Drive Book: Choosing, Using and Maintaining Go-Anywhere Vehicles
Model: 1859606067
Author: Jack Jackson
(1999)
To order this title from Amazon.com, click here.
Haynes Publications
Backroad Adventuring in Your Sport Utility Vehicle
Model: 0071581863
Author: Jonathan Hanson and Roseann Beggy Hanson
(1998)
To order this title from Amazon.com, click here.
4-Wheel Freedom: The Art of Off-Road Driving
Model: 0873648919
Author: Brad Delong
(1996)
To order this title from Amazon.com, click here.
Palladin Press
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