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mjp2

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The lack of mounting options on my early '21 Badlands was disappointing so I decided to fix it. Lots of photos and vendor mentions ahead.

I ordered roll bar protectors from @StickerFab so I'd have a reference point for drilling the holes:
https://www.stickerfab.com/products...2022-2023-up-anti-roll-beam-guard-accessories

I also ordered the flip-down attic shelf from @Mountains2Metal since I really wanted it and it was on sale. :) I went with the large speaker option to future-proof against my own tendencies.
https://mountains2metal.com/flip-down-attic-shelf-factory-speaker-compatible/

I was already running @Mabett 's roll bar protectors and planned on modifying them for continued use. Step 1 was to remove them.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_220650535


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_221114871


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_221352697


To fully remove the covers I had to remove 1 bracket from each of the @BA OffRoad molle panels. 2 screws on each side and I was in the clear.

With those removed (they were pretty scuffed up, which meant they were doing their job well) I had access to the bare bars so work could begin.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_222424345


Bolted up the attic shelf to the brackets that did exist so I could use it as a reference when I needed to.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_233244162.MP


Lined up the roll bar protector on the passenger side and used an automatic center punch to mark the location.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240831_234813313


It was getting dark at this point so I didn't get any photos of the drilling process. My recommendation is to get the proper step bit rather than just using what you have laying around, which is what I did. I actually had the right size rivnuts laying around , as my wife said, "because of course you do." Also had the installation tool on hand so this job came in pretty cheap for me.

I used a standard metal 7/16" drill bit, which was more hassle than it should have been. My step bit didn't have 7/16" so it wasn't what I reached for first, but more on that later.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_000825918


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_001150331


With that in place I had a point of reference from which to continue but it was getting late.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_001532876


(more to come in this thread)
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mjp2

mjp2

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Day 2 was a short one. I was fitting in the work when I could find the time.

With the first side sort-of mounted I used the attic shelf along with the roll bar protector as my reference points for the second side. I made sure things were level when marking the next drill point.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_153248400


Temporarily bolted up with the single mount while I sorted out side 2.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_153251844


Drilling with a regular bit led to a less-than-round hole so I pulled out the ol' step bit to get me close to the right size before finishing the drilling with a regular metal bit.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_155048176


One important thing -- use cutting fluid when drilling into metal. I always have Tap Magic on hand and it got a lot of use during this project.

More-round hole of the right size:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_155214617


Salt is spread everywhere around here in the winter, and I drive on the beach pretty regularly, so bare metal is a no-no even if it's interior. I coated every drilled hole with POR-15 and coated all threads with anti-seize.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_155523082


Rivnut install time, which didn't actually happen until the next day because family responsibilities called.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240901_160519128


Payoff from the next day:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_153935403
 
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mjp2

mjp2

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Continuing with day 3, when I was actually able to spend some real time on this and get it wrapped up...

I was now able to get the stops in place and mark where the side holes would be drilled. Each mounting hole on the M2M shelf is elongated to ensure easy fitment so I made sure all reference points were at the center of the openings.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_154513791


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_154518597


More drilling and rivnuts.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_155706342


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_160517667


Alignment is looking pretty good relative to the protector so I marked and drilled the second location for future use.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_160710035


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_163558002


Drilled out the Mabett roll bar protector (poorly) and got that re-mounted.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_164706282


Repeat on the other side to finish the side I first started on.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_165401491


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_170708408


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_170852712


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_172034738


The payoff:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_172851951


And yes that's anti-seize all over everything. Can't open that can without ending up looking like The Tin Man.

Everything's all nice and level:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_174419722


Checking out how it looks with the top fully down:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180713880


My @BA OffRoad tailgate shelf got a lot of use during this project :cool:

Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180723879


And the finished product, complete with everything re-mounted and ready to go:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180852132


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


The @Mountains2Metal shelf is really a sweet piece. Install would probably take 30 minutes if the mounting locations already existed. In my case having the shelf and mounts as reference points made the rest of the project possible.

Random, but I truly appreciate all the vendors that have stepped up and made some great products for these Broncos. I'm happy to give each of you my business because my truck comes out better for it. :)
 

indio22

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Day 2 was a short one. I was fitting in the work when I could find the time.

With the first side sort-of mounted I used the attic shelf along with the roll bar protector as my reference points for the second side. I had sure things were level when marking the next drill point.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


Temporarily bolted up with the single mount while I sorted out side 2.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


Drilling with a regular bit let to a less-than-round hole so I pulled out the ol' step bit to get me close to the right size before finishing the drilling with a regular metal bit.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


One important thing -- cutting fluid when drilling into metal. I always have Tap Magic on hand and it got a lot of use during this project.

More-round hole of the right size:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


Salt is spread everywhere around here in the winter, and I drive on the beach pretty regularly, so bare metal is a no-no even if it's interior. I coated every drilled hole with POR-15 and coated all threads with anti-seize.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


Rivnut install time, which didn't actually happen until the next day because family responsibilities called.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183


Payoff from the next day:
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) PXL_20240902_180902183
I recall reading somewhere the roll cage is made of some special high strength steel, not sure if that was just marketing speak though. How much effort was required to drill the holes? Did the drill bits hold up well?
 
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mjp2

mjp2

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I recall reading somewhere the roll cage is made of some special high strength steel, not sure if that was just marketing speak though. How much effort was required to drill the holes? Did the drill bits hold up well?
It's marketing-ish unless you have the right tools. The step bit went through it like butter.

I started off with a fresh pack of these and, after the job was done, they were all pretty trashed: https://www.amazon.com/dp/B0B9ZPWHXC

Once I had the method down I used those bits to make the pilot hole, which I'd then enlarge with the step bit, and would then finish up with the larger portion of the 7/16" bit.

If I were buying tools for the project I'd just make sure to get a step bit with a 7/16" step. Mine jumps from 3/8" to 1/2"
 

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If your ends up squeaking and rattling after everything is tightened up like mine did. Use 3 rubber washers on each side to eliminate side to side movement. It still tilts down smoothly after that.
 
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mjp2

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If your ends up squeaking and rattling after everything is tightened up like mine did. Use 3 rubber washers on each side to eliminate side to side movement. It still tilts down smoothly after that.
Thank you for the heads up! Any suggestion that reduces the random creaks, squeaks, and rattles of this truck is welcome. :cool:
 

RuddyMuts

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I have to ask....Did you level the truck first?
 
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mjp2

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I have to ask....Did you level the truck first?
I was waiting for that question to come up 😄

Yes I made sure the truck was on a level spot in the driveway before starting. The shelf is parallel with the rear bumper, so it's only as bad as the '21 build quality...whatever that's worth lol
 

RuddyMuts

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I was waiting for that question to come up 😄

Yes I made sure the truck was on a level spot in the driveway before starting. The shelf is parallel with the rear bumper, so it's only as bad as the '21 build quality...whatever that's worth lol
Looks good! Had to be a little pucker factor pulling the trigger on that first hole 😆
 

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mjp2

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Looks good! Had to be a little pucker factor pulling the trigger on that first hole 😆
I had that "well, we're gonna see if this is as tough as people say it is" moment while my neighbor looked on in horror as I took the drill to my truck.

Despite the drilling this still counts as "accessorizing" rather than "modifying" in my book. I had to promise my wife I wouldn't dive into this truck like I've done to past vehicles...
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt
 

redone17

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I’ve been wanting to do this. How to figure out exactly where the holes are from factory is why I’ve been putting it off. Nicely done.
 

Cobrafang

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The lack of mounting options on my early '21 Badlands was disappointing so I decided to fix it. Lots of photos and vendor mentions ahead.

I ordered roll bar protectors from @StickerFab so I'd have a reference point for drilling the holes:
https://www.stickerfab.com/products...2022-2023-up-anti-roll-beam-guard-accessories

I also ordered the flip-down attic shelf from @Mountains2Metal since I really wanted it and it was on sale. :) I went with the large speaker option to future-proof against my own tendencies.
https://mountains2metal.com/flip-down-attic-shelf-factory-speaker-compatible/

I was already running @Mabett 's roll bar protectors and planned on modifying them for continued use. Step 1 was to remove them.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


To fully remove the covers I had to remove 1 bracket from each of the @BA OffRoad molle panels. 2 screws on each side and I was in the clear.

With those removed (they were pretty scuffed up, which meant they were doing their job well) I had access to the bare bars so work could begin.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


Bolted up the attic shelf to the brackets that did exist so I could use it as a reference when I needed to.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


Lined up the roll bar protector on the passenger side and used an automatic center punch to mark the location.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


It was getting dark at this point so I didn't get any photos of the drilling process. My recommendation is to get the proper step bit rather than just using what you have laying around, which is what I did. I actually had the right size rivnuts laying around , as my wife said, "because of course you do." Also had the installation tool on hand so this job came in pretty cheap for me.

I used a standard metal 7/16" drill bit, which was more hassle than it should have been. My step bit didn't have 7/16" so it wasn't what I reached for first, but more on that later.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


With that in place I had a point of reference from which to continue but it was getting late.
Ford Bronco '21 roll bar rivet nuts retrofitted (mounting holes / locations drilled in rollbar) 1725386822735-xt


(more to come in this thread)
PM sent
 

emore93x

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Good call on the cobalt drill bits.
Tried it without them and killed 2 bits and barely made a dent in the roll bar.

Thanks for the write up.
I basically did the same steps finished in about 3 hours (start to finish) including vacuuming out the metal chips and cleaning up the interior.
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