PSA For you folks that are removing / modifying the crash bars to install bigger tires.....

[NeptuneRanger]

Great post ! I was fortunate to spend a full day at the International Institute of Highway Safety in Arlington VA. Got to watch perfectly good brand new cars (bought off dealer lots by the way) get demolished in offset crashes. Then go down and scratch and sniff the wreckage. Beyond eye opening !! They purposely don’t crash many trucks, but the point that was brought home time and time again are leg injuries. We sit up high, in colliding with an auto the offset impact sheers through bottom portion of the truck like someone horizontally cutting a birthday cake. They had some wrecked trucks on display as I recall, so gnarly. For me personally, I trust the engineers at Ford about where they put those bars and won’t mess with them. For those that do, make them as sturdy as possible.

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[Trigganometry]

John, I applaud your wanting to get the message out there that the crash bars from factory are there for a reason and “cutting them off” is not the wisest move if you still want the “designed” protection they offer. Both of us being Engineer’s will most likely have seeing things differently just from personal experiences. In a way that’s a good thing. It makes us question our reasoning and reassess our thought analysis.

One observation I had seeing some of the photos is the amount of insertion of the factory bar into its mating tube. Seems that only 3” or so past the outer bolt hole it ends. Personally if the crash bar was in the mating tube 6” to 9” farther the strength increases exponentially. It would most likely fail at the holes.

 

[CaliBee]

The crash bars are part of the crumple zone. They are probably designed to deform in a predictable way so that they absorb some of the kinetic energy of a crash. If they are too rigid and too strong, they won't be as effective.

 

[Glocker]

As you can see, I've removed the front bar from my truck. This allows me better approach on obstacles when out wheeling. I can place a front tire on a step obstacle and then power over it without the crash bar making contact with the obstacle before the tire.

However, I have left the rear crash bar in place. I know the tire won't be captured between the crash bars, but at least the rear one's still being in place will keep it from ending up going through the floor. I don't see myself going larger than a 275/70/R17 tire, so I will be able to keep that rear crash bar in place.

I guess one would consider it a calculated risk.

 

[docarter]

Rick I've got FEA right here at home on my computer. That would be a good start, but the aftermarket designs need verified by actual destructive testing.

Not sure why you are writing "hardening as it is getting cut"? The aftermarket crash bars are weldments, made from mild steel, not tempered steel. If they were tempered steel they would break upon impact. You don't want tempered steel.. you want mild steel.

Truth is I haven't found anybody making crash bars that have done any testing at all and that's the point of this thread.

Manufacturers make claims that aren't backed up. IMO that's criminal. Making comments like "Beefy" is ludicrous marketing hype to get folks to buy their products... and it works.

In EU and Aus they do have crash-tested aftermarket bumpers.

https://www.afr.com/companies/bang-goes-5000-as-aami-tests-bumpers-19920221-kaog2

 

[AdamHarris]

Crash bar anti-removalists: 1 and only 1 Question: Ford deletes them on Sasquatch Broncos from the factory. Explain.

 

[docarter]

Crash bar anti-removalists: 1 and only 1 Question: Ford deletes them on Sasquatch Broncos from the factory. Explain.

They remove the bars for the Raptor, too. It's buyer preference and gov't compliance.

99% of buyers will prefer a safer vehicle, the 1% that buy the Raptor / Sasquatch versions obviously are more interested in the off-road performance. Ford doesn't have to put the crash impingement bars in as NHSTA doesn't require them. NHSTA is making its tests more difficult, so this calculus may change soon.

 

[THLONE]

Probably 90% of the people who remove crash bars to install larger tires do so for the "look at me", and have no intention going off the pavement.

 

[gwhalin]

Who cares? It is their truck that they paid for. They aren’t breaking the law. Seems they can do what they want.

Let me try some weird made up stats and motivations.

- 90% of people who install a tune aren’t racing these trucks.
- 90% of people who get tow package aren’t towing
- 90% of people who get tailgate damper aren’t putting anything in their bed

They are all just doing it to look cool!

 

[JACKSMYDOG]

IMO the rarity of conditions that would have to come together to cause the collision which would drive the wheel into the cab, is almost only possibly in a crash lab. It could happen and undoubtedly has, but incredibly rare I think. Also an impact of that magnitude, would likely be so devastating few would survive anyway.

With that said, I know I would be 100% liable for damages that occurred as a result of any safety equipment I remove.

 

[Fitzmotor]

The crash bars, they are like seat belts, roll bars and helmets, totally unnecessary and a nuisance............... until you need one, then you are screwed without it.

But I've always said, "every man has a right to live or die by his own choices" but just don't take out someone else.

 

[OFC Ranger]

I'm designing a mod so I can mount gas cans to the front bumper so in the event of a collision I will be more cushioned.

 

[JesseS]

With that said, I know I would be 100% liable for damages that occurred as a result of any safety equipment I remove.

Vehicle damage is the least of my worries, If my passenger in the front seat looses a leg in a offset crash I could lose everything I have spent 50 years working for if I removed the crash bars. The insurance company will NOT pay a cent for medical if they can get out of it, and a jury will for sure find you guilty of negligence.

 

[D Fresh]

The crash bars, they are like seat belts, roll bars and helmets, totally unnecessary and a nuisance............... until you need one, then you are screwed without it.

But I've always said, "every man has a right to live or die by his own choices" but just don't take out someone else.

Agreed.

Just wanted to add on regarding that last bit.

I drive my wife and kids around. And every now and again somebody else drives my truck, wife, kid, friend, service tech, etc.

On top of the, possible although unlikely, legal liability I had to consider my conscience. If a loved one, or stranger, were to suffer a lifelong injury due to my need to be "cool" I couldn't live with myself.

33"s are as big as I wanted and they can be fit without removing the crashbars. Width of tire and poke are simply cosmetic, they do nothing for offroad performance, so why risk it?

 

[JACKSMYDOG]

Vehicle damage is the least of my worries, If my passenger in the front seat looses a leg in a offset crash I could lose everything I have spent 50 years working for if I removed the crash bars. The insurance company will NOT pay a cent for medical if they can get out of it, and a jury will for sure find you guilty of negligence.

I'm not sure why you quote me on that?

I would be 100% liable for damages (medical and personal) that occurred as a result of any safety equipment I remove.

I don't care about the vehicle either, certainly not more than the passengers safety, including my own.

I am okay removing them because of the odds of the indecent required to cause the wheel to come into the cab and therefore cause damage to my feet or the passengers feet is almost impossibly low. Not because I care about the truck more than my feet.

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