Reproducing roll bar with 2.5" tubing.

[ghetdjc320]

This is the best idea imo. But 20 gauge is particularly thin. Mandrel bent exhaust tubing that is 16 or 14 gauge is the way to go here imho. I’ve also looked into doing this. Thbest I could figure is to just sell the 5 bend pieces and the mounting plates. Then let the end user get the straight 3” tubing locally and weld it up. Heck, you could pack that up into a fairly compact box.

[MagicJames]

Got a 4-cylinder chief that needed one, and I'm honestly not willing to spend twice the price of the truck to buy the sport bar. 

 

Took about a couple of weeks to do this one, just messing with it after work. I'm not the best fabricator, and this would probably be my first and last time doing it. If you're thinking about doing it, I'd say give it a go, it's really easier than you think. The hardest part is the bends coming down next to the bed. You gotta do them in very small sections to get the bends right, and even then, they still look slightly off, but I'm sure a more experienced welder with a proper mould would do them right. I just eyeballed everything from photos. 
 

So yeah, I think the prices some people ask for the originals are crazy, and we shouldn't be entertaining those prices. If you're thinking about it, give it a go; you can even hide the welds like I did for a smoother finish.  

[Chad R]

Looks good

[JZLAJeep]

3 hours ago, MagicJames said:

Took about a couple of weeks to do this one, just messing with it after work. I'm not the best fabricator, and this would probably be my first and last time doing it.

Wow you did an awesome job! This shouldn't be your last time!

[fiatslug87]