BAJA bull guard - one difficult bolt

[Wolford678]

No. Wrong again. That bolt is just being used as demonstration for the photo you required. The other provided bolts are the same length and will not fit that one spot. I’ve also had my professional shop Off Road Warehouse Marietta, GA, advise me of this issue. Someone who welded it on a jig did so at an improper angle. Will you guys going to send me a non-defective replacement?

Understood, it’s always tougher to rectify this kind of issue indirectly but I promise you we will make this right for you.

To the best of my knowledge we’ve never run into this before.

I’d hate to ask you to do one more thing but can you please send me your name phone number and address either by DM here or to [email protected]?

I just want to be sure we are sending any replacement parts to the proper address.

Thank you very much for responding. It seems I put you on blast, but have since edited my post towards CJ Pony Parts.com where I purchased this item.
It’s just a little frustrating sending 5 emails asking for a replacement when an “on sale” item project doesn't go smoothly.
From not being able to remove bolts, buying special torx plus bits and an impact driver, paying a shop to install it, etc.
And now I’m finding out it’s defective. So anyone should be able to see how I’ve put a couple hundred dollars and too many hours into what should have been a 20 minute bolt on install.
I will continue to wait to see if CJ Pony parts.com are going to come through. They may being using a 3rd party customer service provider who has been playing too long of a game of email tag. That’s what lead me to “call them out” on BroncoG6 forum.

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[Lifeliberty]

I installed this Christmas day. You have to put the bolt on the baja bar and then place in the bumper, holding the bar up off the bumper as you thread in the bolt. The head of the bolt should always be in the plate as you tighten. That's the only way to get that bolt in there.

Whole job was 20 minutes, but I knew what to expect as I already had the turn bull bar on there

Show a picture of your other side for comparison.

I bet the shop was lazy

The only thing I can think bad product is if the weld is closer to that hole than it is in the other side. I can take a Pic of mine if you want

Thera a Pic of mine on the turn site in the reviews, the blue one. https://turnoffroad.com/products/2021-ford-bronco-oem-modular-bumper-baja-bull-bar

You have to use the supplied bolt, can't use the bronco bolts with Torx P head, The same bolts that you use right under the grill

. Almost looks like you should be able to get the bolt wiggled in that hole with it off the bumper, then keeping the head flush on the bar mount bracket get it to thread into the bolt/bracket on the bumper.

Exactly correct

 

[Wolford678]

Well you were right. On the “problem side” the weld is directly up on the side of the hole for the bolt. On the other side where the bolt was able to fit there is more space between the bolt head and the weld. (That space is occupied by the washer, but is there.) so the defect is not the angle of the weld, but the location of the hole which is the issue? Either way I’m still not able to fit their supplied bolt. I’m not using the bronco button head Torx plus 40 bolts either. As you see I used the supplied bolts successfully on the passenger side. But the front driver side bolt won’t go in.

See pics below:

 

[Wolford678]

Well you were right. On the “problem side” the weld is directly up on the side of the hole for the bolt. On the other side where the bolt was able to fit there is more space between the bolt head and the weld. (That space is occupied by the washer, but is there.) so the defect is not the angle of the weld, but the location of the hole which is the issue? Either way I’m still not able to fit their supplied bolt. This bull guard is a pain in my ___.

See pics below:

Hmm.

The plate with the bolt holes can't be misaligned - it will only line up on the bumper one way. And all the photos show that bull bar having a really low clearance/aggressive angle like that. So if the holes line up - it's not a manufacturing defect.

And plenty of other people have this same bull bar. I do not, so I can't comment personally, but I don't think you got serial number 001. Hopefully someone with this same item can chime in and say what they did. Almost looks like you should be able to get the bolt wiggled in that hole with it off the bumper, then keeping the head flush on the bar mount bracket get it to thread into the bolt/bracket on the bumper. But I don't have one so I can't say for sure.

That said - I do agree, TOR should be able to help you out here. A shame they didn't, or at least haven't yet. I'm assuming there's nothing in the installation manual/video that addresses this? And there isn't a special bolt or other hardware for that one clearance point?

What I’ve found out on here is the problem hole is welded a little bit closer to the hole than other side where it worked. It’s just enough to prevent the bolt from going it. And it’s close enough to drive me crazy.

 

[Lifeliberty]

If you were closer i'd say come over. On the side that had 2 bolts in, I'm assuming passenger side, remove the rear "turn" bolt and that's where a bronco bolt goes. You should have some spare bronco bolts from where the turn bolts were put in under the grill, and the 2 from under the welded corners. Looking at your pics you should have 5 spares in hand the shop gave back to you.

The next step is removing all bolts, nothing should be stuck at this point, using hand tools. Then try putting the bar back on, but the only 2 bolts that you thread in first are the corner points. You thread in a little bit on one side, (not all the way down), then go to the other side, holding the bar up as you thread a little.... then going back and forth until this bolts are down. Then bolt the rest of the bolts.

Everything is bolted loosely until it's right then tighten

This way you know if those bolts will fit before bolting everything or if you should leave the bar off for a replacement OR just get the turn bull bar which is a lot easier

Sorry you are frustrated, but that is how you learn

Even if the washer sits on the weld you will be fine

 

[Wolford678]

If you were closer i'd say come over. On the side that had 2 bolts in, I'm assuming passenger side, remove the rear "turn" bolt and that's where a bronco bolt goes. You should have some spare bronco bolts from where the turn bolts were put in under the grill, and the 2 from under the welded corners. Looking at your pics you should have 5 spares in hand the shop gave back to you.

The next step is removing all bolts, nothing should be stuck at this point, using hand tools. Then try putting the bar back on, but the only 2 bolts that you thread in first are the corner points. You thread in a little bit on one side, (not all the way down), then go to the other side, holding the bar up as you thread a little.... then going back and forth until this bolts are down. Then bolt the rest of the bolts.

Everything is bolted loosely until it's right then tighten

This way you know if those bolts will fit before bolting everything or if you should leave the bar off for a replacement OR just get the turn bull bar which is a lot easier

Sorry you are frustrated, but that is how you learn

Even if the washer sits on the weld you will be fine

Thanks for the advice. This is the best strategy for sure. I noticed the shop put that “turn” bolt there too. Either way I have spares of both styles of bolts. That hole is too tight to fit the bolt because of the proximity of the hole to the weld is my current theory. It’s just tight enough to make it not doable. I may try it again or try hammering it but I’m sure it’s not going in.

 

[Lifeliberty]

You won't know if it will fit in that hole until you remove the bar. Once the bar is off, insert bolt(without bar on bumper, or near bumper, just hold the bar and bolt in your hand). If it fits then install was bad. If there is no way it will fit, then you need a new bar. do not hammer it. You shouldn't need a hammer for that, if you do then I'd return the bar

If I Remember correctly, the driver side was tighter fit than passenger side.

Good luck

 

[Wolford678]

Thanks. But it won’t go in the hole at all. Even with it off. I’m trying to get them to ship me a replacement, but I don’t think they’re convinced.

You won't know if it will fit in that hole until you remove the bar. Once the bar is off, insert bolt(without bar on bumper, or near bumper, just hold the bar and bolt in your hand). If it fits then install was bad. If there is no way it will fit, then you need a new bar. do not hammer it. You shouldn't need a hammer for that, if you do then I'd return the bar

If I Remember correctly, the driver side was tighter fit than passenger side.

Good luck

 

[kahunabob]

That is too bad about CJ hassling you with a solution to your issue. But, I think Cole at Turn intends to make things right with you. Maybe take the issue offline and deal directly with Cole?

It is refreshing to see Turn is willing to fix this situation.

 

[Wolford678]

That is too bad about CJ hassling you with a solution to your issue. But, I think Cole at Turn intends to make things right with you. Maybe take the issue offline and deal directly with Cole?

It is refreshing to see Turn is willing to fix this situation.

Yep. I just wanted CJ to quick ship me a new one and I’ll ship this one back so I can have my ride squared away. If you knew how much time I’ve spent on this project it’s insane.

 

[Brian_B]

Yep. I just wanted CJ to quick ship me a new one and I’ll ship this one back so I can have my ride squared away. If you knew how much time I’ve spent on this project it’s insane.

Well the good news is mods don’t get any easier

You just get better at it

 

[Squatch]

It looks like you need to unbolt everything, lay that short bolt on its side along the overlong measurement of the opening, and let it drop in from the inside (between bar uprights), and then line up the holes with the mod bumper at the same time.

Can we get a video of you trying that?

...and your VIN#

White arrow, then red arrow:

 

[Wolford678]

It looks like you need to unbolt everything, lay that short bolt on its side along the overlong measurement of the opening, and let it drop in from the inside (between bar uprights), and then line up the holes with the mod bumper at the same time.

Can we get a video of you trying that?

...and your VIN#

White arrow, then red arrow:

It’s been tried. I even paid a shop $$$ and drove hours in traffic. No video coming soon sadly. I’m too busy working

 

[HoosierDaddy]

Damn, that's a tight fit!

 

[Squatch]

Damn, that's a tight fit!

Yup, times like that you may have to end up screwing the other way and put a nut on the backside.

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