Installing the Nerf Bars

I wanted to install nerf bars both to protect the truck from damage and improve the appearance. The body lift leaves a lot of ugly frame exposed. I like the look of Smitty-bilts, and they only cost $125. I bought a set made to fit the pre '84 short bed, but they don't sell a body lift version of this length. That was just as well as the original front bracket is a wimpy little thing that bolts to the transfer case cross member. I got together with my son-in-law's father, who has a garage full of neat tools, including an air compressor and MIG welder. He cut the old brackets off the pipes, and we fabbed up new brackets from some 2 inch wide steel stock from OSH. We mounted the bars on the opposite sides of the truck from the original design to use the original brackets with the bolts down to lift the bars up under the body, and hide the frame. We mounted the brackets with bolts, then tack welded the front of the bars. Pulled down the bars and finished the welds, painted them up and bolted them in. We then tack welded the top of the brackets to the frame for extra strength and to prevent the leverage of weight on top of the bars from pulling them away from the frame. We welded them in a spot that should be easy to cut loose if I need to remove them. The right rear bracket holes had to be carefully placed to avoid hitting the emergency brake cables.

	Closeup of the welded up steel bracket. The weld is ground off where the pipe will sit, and the mounting holes are marked to drill.
	The finished bracket, painted and ready to install on the truck.
	The Smitty-bilt original rear bracket. We duplicated this bracket for the front end.
	My son-in-law's father under my truck, welding the nerf bar. His garage is full of great tools.
	Close up of the weld on one bracket of the bars, prior to final paint touchup. This was placed to be easily cut if I need to remove them.