Boulder Bar Install

BostonJohn · **Posted:** Fri Jan 25, 2008 4:50 pm

So I finally got my boulder bars!!! With all the rain we'll be getting this weekend (+ my lack of a garage) i'll have to hold off on the install :cry:

Does any one have some tips, suggestions, things to watch out for during the install? I didn't see any posts in the tech sections so I figured i'd see if anyone had words of wisdom before I start drilling holes.

raceinfan · **Posted:** Fri Jan 25, 2008 4:54 pm

if you can get a 90 degree drill to make sure your back holes are straight it would be a big help but if not it'll be fine also

Jeepjeepster · **Posted:** Fri Jan 25, 2008 9:21 pm

Take your time and double check everything before you drill a hole.

bugnout · **Posted:** Fri Jan 25, 2008 11:44 pm

Mine came with a drilling guide, a piece of metal with holes drilled in it that matched the holes in the pinch weld tube part of the sliders. I couldn't figure out how to position it without actually seeing the sliders in place. So I took two jack stands to hold the outside of the bar and 2 C clamps to hold the mounting plates to the frame rails. Used a rolling hydralic jack to push it up tight to the bottom of the KJ

Once I had it positioned where I wanted it set on the jack stands, I clamped the frame rail plates with the C clamps then drilled the first hole in the pinch weld at the front and put a bolt through it. With that as a guide I marked the rest of the holes with the drill, but did not try to go all the way through, then I removed the sliders to finish drilling the holes. It was much easier to drill the holes without the slider in place. Just got to be careful to get them parallel and don't let the drill wander.

After I had all the pinch weld holes drilled, i positioned the sliders in place and put a couple bolts in. Finally I drilled the holes for the frame rail plates and drove the self tapping screws in.

Repeat for the other side, except you probably want to take a couple of measurements to make sure the position matches.

Last tip, Get a new drill bit and use a little cutting oil to keep it cool.

jeepskate · **Posted:** Sat Jan 26, 2008 1:57 am

What he said.

Here are the installation instructions from All Js:

http://www.boulderbars.com/KJ/2002-2006KJBoulderBarsInstallationDirections.doc

One more piece of advice: If you don't have the template, yank off the trim and remove the screw in the pinch weld at the bottom of the front fender (you have to do that anyway). Bolt the boulder bar into that first hole (You might have to drill out that hole to widen it a little bit first). Then use a jack to hold the other end of the boulder bar up and use a center punch or a pen or whatever you like to mark the locations of the other holes you'll need to drill in the pinch weld. Once you've got those drilled you can loosely fasten all the bolts through the pinch weld and use the jack to keep it in place while you mark the inside holes to drill.

Oh, and you probably know this, but you need an F drill bit

tommudd · **Posted:** Sat Jan 26, 2008 2:19 am

Stupid question I know but where did you find an F bit except for AllJs? Been to two hardware stores and they look at me in some kind of dazed eyes...like DUH an F Bit ????

Thanks

jeepskate · **Posted:** Sat Jan 26, 2008 3:12 am

tommudd wrote:

Stupid question I know but where did you find an F bit except for AllJs? Been to two hardware stores and they look at me in some kind of dazed eyes...like DUH an F Bit ????

Thanks

I bought my boulder bars used, so I had to order the F bit online cuz I couldn't find one locally and didn't want to drive all the way up the mountain just for a bit. You can find em on Amazon, but you'll probably pay more for shipping than for the bit itself. I think I paid around 10 bucks total.

jeepskate · **Posted:** Sat Jan 26, 2008 3:16 am

raceinfan wrote:

if you can get a 90 degree drill to make sure your back holes are straight it would be a big help but if not it'll be fine also

I wish I'd had one. Those back holes are a bit of a PITA otherwise.

tommudd · **Posted:** Sat Jan 26, 2008 4:43 am

The boulder bars I have are used as well, never installed them as I dont have the bit .... :cry:

hatu · **Posted:** Sat Jan 26, 2008 8:15 am

tommudd wrote:

The boulder bars I have are used as well, never installed them as I dont have the bit .... :cry:

Tom, I just got my bars and the bit and right angle drill, do you want to get an install party going?

Dave

dloc_jeep_KJ · **Posted:** Sat Jan 26, 2008 1:31 pm

yeah drilling in the pinch weld is a PITA for sure. i didnt have a "F" bit when i did mine. u can do it though w/ a cobalt bit and by drilling a pilot hole first. oh and a lot of time.. i will be getting a F bit to put my sliders on for sure

BostonJohn · **Posted:** Sat Jan 26, 2008 4:34 pm

Thanks for the tips guys. I was worried about finding an "F" bit. Gonna have to order one online I guess.

Signcutter21 · **Posted:** Sat Jan 26, 2008 5:45 pm

Shoot All Js and ask them about getting you one or find out what the standard conversion is. I ended up having to get the standard size, which was just a bit under F bit size and wobbling it a little. Worked fine for me.

take your time, measure twice and make sure you use the guide on the correct side for the holes. Maybe buy an extra bit while your at it too. Oh and if possible use a DC drill, drained the batteries on my 19.2v.

later,
mike

Boulder Bar Install

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