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Discussion Starter #1
2002-2008 Dodge Ram 2wd

*Note: This article only applies to trucks with 2/4.5 drop with flip kit in rear*

First, long bars are traction bars that attach to the rear axle and frame rail to eliminate leaf spring wrap while creating some lift to help plant your tires. The bars are called long bars due to the length of the bars which are 56" long in this case.

Here is a picture of the finished product minus the rear brackets

 

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To begin building your long bars, make sure you read the first post to ensure your truck matches the qualifications for building the bars to the specs provided in this how-to article.

I will begin by listing the needed materials and tools.

Materials needed:

2- 5' long sticks of 1.50" x 0.125" wall DOM tubing
1- 3/16" thick steel plate 3" wide x 60" long
4- Polyurethane bushings with tubing and grease zerks
(available at www.polyperformance.com part# PPM-4305)
6- 1/2" diameter x 3-1/2" long grade 8 bolts with nuts and lock washers
4- 9/16" diameter x 4" long grade 8 bolts with nuts
Paint- I used Rustoleum appliance epoxy, but the finish is up to you

Tools needed:

Welder- Mig, Tig, Arc (whatever you know how to use well)
Drill or drill press
1/2" and 9/16" drill bits
Wire wheel for drill or bench grinder with wire wheel
Angle grinder with abrasive wheel for steel
Sawzall or chop saw(if you have one)
Socket and wrench set
Vice or welding jig
Tape measure
Marking pen
Hammer
 

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Discussion Starter #3 (Edited)
I would start with building the bars first, since you will need them to test fit your brackets.

*Note: Reference attached drawings for specs when building bars and brackets

1. notch the end of the DOM tubing to accept the 1-7/8" diameter of the tubing that comes with the bushings.

2. Remove the supplied grease zerk and bushing from the bushing tubing and weld the bushing tubing to one side of bar.

3. Ensure that the bar is on a flat surface and mark the tubing on the other end to be notched on the same plane as the first.

4. Weld the bushing tubing on the other end and your bars are ready for test fitting once the brackets are built.

5. Once the welds cool you may use the wire wheel to remove any weld splatter that may be present and to clean the welds.

Here is what the end will look like once you have it finished

 

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Discussion Starter #4
Next, begin by building the rear brackets.

1. Remove the u-bolt plate from the truck and set aside(remember this only works with flip kits)

2. Cut 4 pieces of 3/16" steel plate to the dimensions shown in the attached drawings

3. Drill a 9/16" hole in each plate according to the attached drawings

4. Grind away paint from u-bolt plate in places that welding will occur

5. Tack weld plates onto u-bolt plate according to attached drawings

6. Measure plate dimensions to ensure everything lines up according to attached drawings.

7. Weld plates to u-bolt plate

8. Clean welds with wire wheel

9. Remove remaining finish from u-bolt plate for later painting

10. Reinstall u-bolt plates to ensure proper fit.

Here is a picture of the rear bracket once installed on the truck

 

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Next, we will build the front brackets.

1. Cut 3/16" plate into pieces to weld together according to specs in attached drawings.

Note: For the triangular piece just measure the two sides of the triangle and cut at an angle from one mark to the next and the pieces will have the perfect angle.

2. Drill 1/2" and 9/16" holes in plate according to attached drawings

3. Weld pieces together according to specs in attached drawings

4. Clean all welds with wire wheel

Here is what front brackets will look like when finished


 

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Discussion Starter #6
Next, we will mount the front brackets to the truck and test fit the set-up.

1. Install bushings into long bars

2. Slide bar into rear bracket and hand tighten bolts to allow bar to pivot

3. Attach bar to front bracket before mounting front bracket to rame rail

4. Lift the front bracket with bar attached and hold in place to frame rail

*Note: 1" lip on front bracket is to rest against underside of frame rail.

5. Mark holes to be drilled on frame rail

6. Drill holes with 1/2" drill bit

7. Lift front bracket and bar to frame rail and bolt fron bracket to frame rail to ensure proper fit

8. Remove brackets, bars, and bushings from bars once test fitted properly and paint or powdercoat depending on your desires

9. Reninstall bushings and install grease zerks to bushing tubing

10. Install bracket to frame rails and install rear brackets and torque to manufacturer specs

11. Install bars and enjoy your new mod

Here are the drawings for you to reference during build process.
 

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Discussion Starter #7
Here is a compilation of finished pics installed on my truck.





 

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End.
 
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