IT'S DONE. AT LAST!!!
I used 40mm dia x 6mm thick mild steel boiler piping. 4 pieces of 1800mm each.
The bracket for the front part consists of 12mm steel plate, 400mm x 100mm. I welded plates 100mm x 100mm onto the plate for the bolts to attach to the chassis. On my Patrol there are two areas at the front - left & right - where the body is attached to the chassis, that allow for a bracket to be bolted to the chassis.
The bracket for the back part is 8mm x 200mm x 100mm. These are welded onto the another 400mm x 100mm x 12mm m/s plate. This brackets ''grab onto the chassis, with two M12 bolts "clamping" it to frame. The brackets are designed to so that the bottom of the pipes are level with the chassis, maintaining ground clearance.
The 16mm m/s support braces welded to the bottom will pr event the brackets from bending upwards, as well as to scrape or break any rocks / dirt that might pose a snag risk. The area of most impact is right below the 4500 insignia. as can be seen....
In this case, functionality and practicality overrides aesthetic value. Like most things 4x4, practicality rules the roost. For some bizarre reason my wife doesn't like the ARB replacement bumper
Why o Why...Anyhow, I've decided to keep the rails as close the vehicle and not too far out. The further from the vehicle, the longer the ''cantilever'' and the weaker the brackets. I also seen guys spending a lot of money fitting side steps to prevent damage to the side sills, but they are too weak is not made to protect the vehicle.
It might be a bit late, because the damage is done. But now I can get it repaired. I was thinking of cladding the sill with 5mm aluminium "vastrap" plate; ought to look nice...
I'm going to test the setup this weekend at the George's valley 4x4 event!!
. Gonna be GREAT!!
