SAS Package Crash Bar Removal

[MNBigfoot]

Agreed! Unfortunately you can't control other drivers, only try to be proactive and maybe reactive to a shitty situation.

Raising the Bronco's center of gravity, by means of larger tires or lift will have more effect on safety than those little bars being removed. If you want to be safe, pick up a set of 30" tires from a Base Bronco.

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[Bikeric]

Some companies manufacture replacement inserts such as these: https://www.extremeterrain.com/readylift-bronco-high-clearance-anti-intrustion-beams-67-21200.html?utm_content=XT Lift Kits - Lift Kits|ReadyLIFT&T5_Var4=FB18384&utm_campaign=XTB+Bronco+Vehicle+Medium+LTVTop&dialogtech=ppc&utm_source=google-pla&utm_medium=shopping&T5_Var2=shopping&gclsrc=aw.ds&gad_source=1&gclid=Cj0KCQiA88a5BhDPARIsAFj595gCwc-Vmw4xVUyMAlQ-qbQ9ZBs5TEiENA3A1VeM0HVy9HxhHR3gcsgaArVhEALw_wcB

This is what the front crash bar holder looks like in the process of removal:

There is also a crash bar with a removable insert at the rear of the wheelwell, but I left mine in place when I went to 37's. My setup causes the tire to rub the frame and sway bar disconnect bolt much more forward than that rear location.

 

[N0madK1ng]

The crash bars are there to "capture" the tire, for loss of a better word, during a frontal collision. The tire would be squeezed between the front and rear bar during impact. They help prevent a tire/wheel combo that sits inside the fender from being pushed up into the passenger footwells. On the Sasquatch pkg they are removed since that wider tire/wheel combo sits partially outside of the fender and will act as its own crash bar.

very interesting

 

[crenca]

On the Sasquatch pkg they are removed since that wider tire/wheel combo sits partially outside of the fender and will act as its own crash bar.

Has this been stated by Ford? The (insurance company funded) Institute of Highway Safety small overlap testing prompted most manufactures to add these "crash bars" starting a few years back. This testing found that even with an otherwise adequate safety cage (which I suspect the Bronco has given it's roll-over engineering), often the wheel/tires were protruding into the low wheel wells, causing the vehicle to still fail the test.

If you observe the typical crash test, the suspension "hangs on" to the wheel tire, which "curls back" into the lower wheel well. I suspect a Sasquatched Bronco would be worse, not better, given the size and weight of the wheel and tire package. It will never be tested however given that the IHS only tests typical (often the cheapest) version of each vehicle as they $pay$ for the vehicles themselves so that the manufacturers can not goose the system.

I will be installing an aftermarket 'high clearance' crash bar setup I ordered from Boss 4x4 for my new Sasquatched Bronco this very week. Of course, such a system has never been tested...but it might make a difference in a serious small overlap crash, and it's defiantly worth the bonus points I will get with the wife

 

[Montana Bronco]

Note the flattened sides of this wheel, that is the crash bars doing their job, containing the wheel inside the wheel well during a crash.

My personal choice is to run crash bars. I have the Extreme Terrain ones linked upthread that fit 35’s.

 

[N0madK1ng]

Has this been stated by Ford? The (insurance company funded) Institute of Highway Safety small overlap testing prompted most manufactures to add these "crash bars" starting a few years back. This testing found that even with an otherwise adequate safety cage (which I suspect the Bronco has given it's roll-over engineering), often the wheel/tires were protruding into the low wheel wells, causing the vehicle to still fail the test.

If you observe the typical crash test, the suspension "hangs on" to the wheel tire, which "curls back" into the lower wheel well. I suspect a Sasquatched Bronco would be worse, not better, given the size and weight of the wheel and tire package. It will never be tested however given that the IHS only tests typical (often the cheapest) version of each vehicle as they $pay$ for the vehicles themselves so that the manufacturers can not goose the system.

I will be installing an aftermarket 'high clearance' crash bar setup I ordered from Boss 4x4 for my new Sasquatched Bronco this very week. Of course, such a system has never been tested...but it might make a difference in a serious small overlap crash, and it's defiantly worth the bonus points I will get with the wife

Mind sharing roughly what this costs for part and install? I'm leaning towards doing this as well.

 

[N0madK1ng]

Note the flattened sides of this wheel, that is the crash bars doing their job, containing the wheel inside the wheel well during a crash.

My personal choice is to run crash bars. I have the Extreme Terrain ones linked upthread that fit 35’s.

Thanks for sharing that photo. Puts this into perspective. I'll check out your link above.

 

[MNBigfoot]

Mind sharing roughly what this costs for part and install? I'm leaning towards doing this as well.

It's 2 bolts a piece, if you have kids of any age, it's a great project for them, a 7-year-old could do it (or a 4 year old with help)(you may have to help with the bumper/depending on which one you have).

 

[PizzaBronco]

Icon high clearance crash bars did not fit and I returned them. I bought some from Readylift that fit much better.

Somewhere on this forum there’s a post
from a guy who claims his company builds all of the Bronco frames. He said the crash bars are actually extensions and the sleeves are part of the reinforcement. A lot of time was spent on them. If you’re 33” or less, the crash bars are extremely effective. If you’re sasquatch or 35” (sasquatch does not have the extensions but does have the sleeves) it performs acceptably. He did not think highly of cutting off the sleeves entirely.

(Edit: I didn’t save the post but this is how I remember it. Also it’s the internet, so grain of salt as required)

 

[Bronco_007]

Where did you get your Readylift crash bar? Didn’t see it on their site. The ICON ones are in stock on boss4x4, but curious for more deets on your figment issue. Thanks!

 

[Bronco_007]

Aha! Some sites call them “anti-intrusion beams”.

 

[EasternSierra]

Icon high clearance crash bars did not fit and I returned them. I bought some from Readylift that fit much better.

Somewhere on this forum there’s a post
from a guy who claims his company builds all of the Bronco frames. He said the crash bars are actually extensions and the sleeves are part of the reinforcement. A lot of time was spent on them. If you’re 33” or less, the crash bars are extremely effective. If you’re sasquatch or 35” (sasquatch does not have the extensions but does have the sleeves) it performs acceptably. He did not think highly of cutting off the sleeves entirely.

(Edit: I didn’t save the post but this is how I remember it. Also it’s the internet, so grain of salt as required)

That makes sense. When I look at the sleeves (I'll call them bases) I see reinforced strong points that should help the vehicle move sideways in response to a narrow-offset crash as mentioned by @RagnarKon. Cutting those bases off entirely is going to totally remove their function. IMO you should then expect crash results something like those pickups that had poor results.

 

[TX-Dennis]

As one who has totaled a Sasquatch Bronco by t boning a red light runner, I will say that the crash bars would have made no difference in the outcome of my crash. I suffered a broken sternum from the airbag. It was quite painful, but a crash bar would have made no difference. The Bronco did its job - sacrificed itself to protect the occupant.

Yes, I bought another Sasquatch. So . . .

 

[PizzaBronco]

Anti-intrusion is really a more accurate term. The (only) purpose is to prevent the wheel from getting pushed into the footwell. The combination of the sleeve and the larger 35” tire also helps with that.

I figure the high clearance bars aren’t gonna hurt. The icon bars looked really well made. I was able to get them into the forward sleeves, although it took some fighting. The rear bars just did not fit. I pounded on em with a rubber mallet and got nowhere. Emailed icon, but they took so long to respond that I gave up and was thankfully able to return them. (When they did get back to me it was to basically say “try hitting it harder”). If anything the readylift bars are a little loose. They hide nicely behind the mod bumper and feel burly. I believe 4wp sells their own version too.

 

[crenca]

Mind sharing roughly what this costs for part and install? I'm leaning towards doing this as well.

I ordered this one:

https://www.boss4x4.com/product-p/4wp8-62213.htm

Supposed to arrive tomorrow. I will let you know how it goes.

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