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MUD-UK ulkheadRemovalBarFitting Instructions

f eli 01422-847704www.mudstuff.co.ukThiskit shoutd omprisehe fottowingtems:1 x Butkhead emoval ar'l x Angte ection inishing trip2 x EndDtates2 x Socket ead asteners nd2 washersRivetsTootsReouired:Dritt1omm r 3/86 drittbit3/16bor 4.8mm rittbitCtamping eviceRiveting oot5mmALten eyTo cut the butkhead e recommend singa jigsaw/nibbter/reciprocatingsawor cuttingdisc.A grinding isc s usefut or trimmingback he bodycapping nd idyingup anyrough-cut dges.Usea sawbladesuitabteorcuttingaIuminium.Atways seeyeprotectionwhenusing utting oots.

SteD .Removehe front seat basecushionsi tideseatsas far forward aspossibleand fotd seatback forward.Removal f the centre seat or cubbybox witlmake itting easier; t is however,possibteo instatl he bar without theirremovat.lf you're fitting the butkhead ar at the same ime as itting a pair of MUDseat raits, emoyehe seat rames rom the vehicteat this stage.Coverup as much of the interior as possibtewith a dustsheet s the tinyshards of aluminium generatedwhen cutting the butkhead witt geteverywhere! tways seeyeprotectionwhenusing utting oots.

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SteD2.Removehe top capping rom the central butkhead y dril.ting ut att of therivets.These ivets secure wo strengthning tateson the underside f thebutkheadop rait.The wo strengthening tatesare locatedat either end ofthe butkheadoDrait.

Step3.With the capping emovedraisd ib that runsacrossseatsarrowedA below.ptace he butkheadthe futt width of theremovalbar on toP of thebutkhead ehind he front

Step4.Centratisehe bar and mark a line around he TOP/UPPERdge of thebulkhead aras ttustrated bove.Removehe butkhead ar.Thesectionof the butkheadDanel bove he lineyou've ust markeds the section hat needs o be cut away.

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Step5.Cut away the butkheadpanet ottowing he U.shaped ut-tine you've ustdrawn. f you're usinga jigsaw, emember o use he correct ypeof jigsawbladesuitable or cuttingatuminium.Don't worry oo muchaboutgettinganarrowstraight ine, as his cut edgewitl be hiddenwhenyoucome o fit thefinishingangtestrip onto the main butkheadbar. NOTE:Atwayswear eyeprotection hen uttingaluminium.SteD6.Trim backthe sectionof the front body corner capping n order that thecappingdoesnot protrudebeyondhe upright/vertical aceof the butkheadremovalbar as arrowed n the Dictures etow,Thiscut canbe madebeforecutting he butkheadaneI ut as ttustratedetow ight.

Step7.With the bul.kheadut away,you now need to mark the positionsor thebolthotesn the bodycapping.Theseholesneed o atignwith the targehotein the end ptatewhenpositioned n top of the capping.This s the trickypart...!We recommendmarkinga line on each upright teg of the bulkheadbar asDerarrowA betow.Centratisehe butkhead ar and use he marked ine as aindicator for where to mark the position for the botthoteon the bodycapping.The botthoteshoutdbe just off the edge of the rivet hole asittustratedby B betow.Dritt the capping usingthe 10mm dritt. Bott the end ptates down intobulkheadbar with the fasteners upptied nd then secureusing he threerivets n eachendplate.

Finishedresutt houldtook ike his

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The endptatesarefitted asper the photobelow.Theend of the ptatewiththe two rivetsgoesoward he front of the vehicle.

Rearof car

Note: FactoryStation'Wagonmodels itted with side windowtrim panelsmay equiresomeminor trimming n their ront corners o aid fitting of thebolts thot secure he endplotes into the bulkheadbor. Alternotivelyyoumoy wish to remove the sidepanel completely to occess he bolts-

Step8.The angte-finishingtrip can now be ptacedover he bulkhead ar from therear of the car so that it covers he rough-cutedge.To get a snug itbetween he butkhead ar and the finishingstrip clamp the two togetherusing matloff cuts of timber or simitar o protect he powder oating.Withthe two sectionsctamped ogether, work aLong he bar, drilting into thebutkhead ar through he holes n the finishingstrip and rivet eachhote nturn. Usea gooddritl bit since he steelboxsection s tough.To conceal he rivet heads,you may wish to touch them in usinga smattDaintbrushith satinbtackDaint.why not complimentyour new bulkhead emovalbar with a poir of MUDRdits? hesesimple to instau seot-mountingails provideextro reorwardtravel to offer lront seat occupants o greater degree of comfort ondlegroom. ldeal for taller drivers and owners of loter model Defenderswhere ootwell spoce nd egroom pocesfurther restricted.