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

[mjp2]

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.

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.

Bolted up the attic shelf to the brackets that did exist so I could use it as a reference when I needed to.

Lined up the roll bar protector on the passenger side and used an automatic center punch to mark the location.

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.

With that in place I had a point of reference from which to continue but it was getting late.

(more to come in this thread)

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[mjp2]

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.

Temporarily bolted up with the single mount while I sorted out side 2.

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.

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:

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.

Rivnut install time, which didn't actually happen until the next day because family responsibilities called.

Payoff from the next day:

 

[mjp2]

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.

More drilling and rivnuts.

Alignment is looking pretty good relative to the protector so I marked and drilled the second location for future use.

Drilled out the Mabett roll bar protector (poorly) and got that re-mounted.

Repeat on the other side to finish the side I first started on.

The payoff:

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:

Checking out how it looks with the top fully down:

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

And the finished product, complete with everything re-mounted and ready to go:

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]

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.

Temporarily bolted up with the single mount while I sorted out side 2.

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.

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:

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.

Rivnut install time, which didn't actually happen until the next day because family responsibilities called.

Payoff from the next day:

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?

 

[mjp2]

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"

 

[Dog named Linda]

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.

 

[mjp2]

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.

 

[RuddyMuts]

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

 

[mjp2]

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]

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

 

[mjp2]

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...

 

[redone17]

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]

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.

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.

Bolted up the attic shelf to the brackets that did exist so I could use it as a reference when I needed to.

Lined up the roll bar protector on the passenger side and used an automatic center punch to mark the location.

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.

With that in place I had a point of reference from which to continue but it was getting late.

(more to come in this thread)

PM sent

 

[emore93x]

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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