Words by Bryan Grant
Photography by Bryan Grant and Brook Marrington

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Now that the 4Runner’s suspension was sorted (see Australian 4WD Action Issue 113), I’d been tackling progressively harder tracks. The only problem was the rear end had more overhang than Kim Beasley in a bikini, and the dent collection was continually being expanded.

It got so bad that it actually looked better with no bumper at all. I figured it was time to get the vulnerable body panels some protection that was up to the challenge – as well as somewhere to store the 35in spare wheel.

One of the best things about owning a 4WD is the vast array of products that we can easily get our hands on to improve our vehicles for their intended duties.

Go to your local 4WD specialist store and you would be hard pressed to not find something for your vehicle – bullbars, sidesteps, roof racks and multitudes of other parts stare back at you just waiting to drain your wallet.

The sure-fire way to keep your lower panels resembling a straight line is to protect them with super-tough bar work. But, what happens when that gear doesn’t quite fit the bill for what you’re after?

How the rear end used to sit, pre-bar work. No protection at all!	The stub axle for the swing-away wheel carrier

When you start to really push the envelope off-road, the aftermarket products that are perfect for the touring scene start to come up short. When nothing at the 4WD store fits the bill, why not make something yourself?

There’s also another important issue to consider if you have a modified 4WD. A body lift, as fitted to many 4WDs to clear larger tyres, will bugger up the fitment of standard bar work. The problem is that they’re mounted to the chassis in some way or form – and a body lift moves the body up and away from the chassis.

What’s left over is an unsightly gap between the body and the bar work, and without raising your bullbar, you miss the increased clearance that the body lift affords.

Here you can see the amount of effort that has gone into making the hitch receiver as strong as possible	The rear end had more overhang than Kim Beasley in a bikini

Aftermarket vs Custom

So, how do you figure out if aftermarket or custom bar work is for you? The answer lies in the type of 4WDing that you will be doing.

If you’ve set up your 4WD to tour around Australia and don’t intend on making it climb rock walls, then the simple answer is to stick with the tried-and-tested aftermarket gear available from any number of manufacturers. Their bar work is designed and engineered to deliver exactly what you’re after – increased protection for your vehicle.

So, when does custom bar work come into play? When you start pushing the boundaries of your 4WD, and find that even the aftermarket gear gives you clearance issues, you may need to look into a custom job.

Heavy-duty steel bullbars and rock sliders, like ARB items, may save your panels from dents, but you lose clearance and may find yourself hanging up on the same rocks that were giving you problems before you fitted your lift kit.