I finally have started the 02-03 wagon C-D bar.
Unknowing to me the 02 & up wagons have rear height adjustable seat belts. So that meant a total re-engineering of the side brackets.
after about 3-4 hours or figuring and measuring I finally got it worked out. The V2.0 setup is going to be far more rigid than the 1st bar set that I made for the GC wagon. The 1st set's side brackets actually where bending from the amount of force I could but on then via
the turn buckles. So the side bars are now 1" square tube upgraded from 1/2". The front mounting point on the side bar is a pipe anchor style and no longer attached to the seat belt directly, so seat belt mounts/function is unchanged. The rear mount is the same as the previous C-D bar. Instead of using cheap ebay rear tower bar mounts I had plate steel plasma cut and made my own.....far stronger and closer fitment
. Also making my own turnbuckles again was out of the question. The 1st set litterly ripped the threads out of the female pipe ends, so I out sourced grade 8 turnbuckles along with all grade 8 universal/heim joints and pipe ends. Im figuring with the added strength I may be able to influence camber by .5+/- degrees depending on if the bars are in pulling or pushing tension mode......that remains to be seen appon rear alignment
Here is what is finished so far:
Rear Side Bar Mounting Points
Front Side Bar Mount Points
Rear Strut Tower Mounts
Turnbuckle/Heim Joint Assembly