Fitting Bullbars
Difficulty
Credit
Evilution
Cost
£300ish
For
Old Style 600cc For2
Old Style 700cc For2
Old Style 700cc For2
Fitting Bullbars
So many people rant on about fitting these to the smart and how dangerous they are to pedestrians so I had to get some.
So many people rant on about fitting these to the smart and how dangerous they are to pedestrians so I had to get some.
Front Bull Bar
Firstly you need to remove the front panel which can be found
Remove the lower torx bolt in each side of the front crash bar using a T40 bit.
Reusing the bolt you just removed, fit the long metal strap with the bend near
the top and with the strap angling towards the front of the car.
OK now time to pay attention and go with whatever works.
You get 2 centre brackets, 1 marked cabrio and 1 marked coupe.
Don't let this fool you.From what I can see, coupe means coupe mk1 to mk5,
cabrio means all cabrios mk1 to mk7 and coupes mk6 and mk7.
The dire German instructions don't make things too clear concerning the
fitting of the centre bracket, their instructions show to do it this way,
But I found the fitment to be much better this way around. As you tighten the bolt
with an 8mm socket, it pulls the 2 metal pieces together clamping over the bottom
of the front crash bar. Ensure it's central using the centre fin under the radiator.
Hand tighten all the bolts so you can adjust them in a while.
Attach the bars to the 2 side straps using the 13mm bolts and nuts.
Again hand tighten, centre the whole thing and ensure it is level.
When you are happy with the fitment tighten the T40 bolts at the
top of the straps and the 8mm nut on the centre bracket.
Briefly tighten the other bolts and check the whole thing is straight.
When you are happy, undo the 2 lower nuts and the centre bolt and
take the bar off leaving the straps and support bar in place.
Refit the front panel and refit the bar to the straps and support bracket. Tighten
everything up and check for any fouling of the panels, make any adjustments if necessary
If all is OK, fully refit the front panels then refit the bars. Fully tighten and recheck often.
Important
It is well worth noting that some of the deeper front spoilers are not
compatible with the front bull bar as they foul the lower front edge.
Rear Bull Bar
Remove the rear panels which can be found
Remove the bottom outside Torx45 bolts holding the valance supports.
Take the metal straps with OBEN (means UP in not English) and using
the bolt you just removed refit the new strap so it angles towards you.
With both sides fitted hand tight, hang the rear bar from the straps with the 13mm bolts
and nuts in the kit. Ensure the rear bar is centralised and tighten the top 2 torx bolts.
Tighten all the bolts and ensure everything is dead straight and level.
Remove the 2 lower bolts and take the bar back off the car leaving the straps in place.
Refit the rear panels before refitting the rear bull bar. Tighten everything up.
Important
The rear bar replaces the original exhaust valance straps leaving you nothing to screw the
lower 2 bolts of the valance on to. The way the straps sit, the rear panels press agains the
lower edge of the strap so it can't move, I ran a zip tie around it and through the valance.
Just in case.
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