DIY Push Bar for 2025 Badlands

[Frenchy906]

OK, so since nobody makes an aftermarket push bar for the 2025 Badlands, I’m going to be working with a local company to make a push bar. I’m not sure of how much they’re going to be, or how much interest there is even for one of these, but if anybody is interested, let me know

I do know that the OEM Ford Sasquatch push bar is incredibly expensive as well as in my opinion, quite a bit taller than it needs to be.

My plan is to have these made in 316 stainless with stainless mounting brackets and hardware. I have access to a powder coating machine. And I plan on having them powder coat afterwards.

The company that we’re making the brackets, has a water jet system and multiple CNC machines, so the mounting points will be perfectly spot on. Everything will be tig welded together.

I just need to source the bar material and figure out what the perfect size tubing is. In my head, I am currently envisioning this push bar only being an inch or two above, where the front bumper stops. That way it doesn’t interfere with any of the sensors, and it doesn’t block the bronco badging.

Updates will come as I figure out parts and start the process on this.

this will not be the first time I’ve had custom car parts made by this company. I had them make me a lot of parts that I sold over the years when I owned my Ford fusion.

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[Iamcanadian]

Well the OEM push bar on my Big Bend Black diamond off road package has a 2 inch diameter tubing. Ideally if you already have the Badlands with the metal bumper you just need to get all your measurements off of the OEM push bar from either a friend or even at the dealership and modify the height of the horizontal portion of the bar by approximately 2 to 3 in lower so that it's not blocking the Bronco letters on the grill. That's actually my plan for the summer, pulled the OEM bar off and cut it down and reweld it making it about 2 to 3 inches lower.

 

[Frenchy906]

Well the OEM push bar on my Big Bend Black diamond off road package has a 2 inch diameter tubing. Ideally if you already have the Badlands with the metal bumper you just need to get all your measurements off of the OEM push bar from either a friend or even at the dealership and modify the height of the horizontal portion of the bar by approximately 2 to 3 in lower so that it's not blocking the Bronco letters on the grill. That's actually my plan for the summer, pulled the OEM bar off and cut it down and reweld it making it about 2 to 3 inches lower.

I’m indecisive on if I want to replicate a shorter Sasquatch bar or if I wanna do just kind of like your standard 90° rounded corners. Either way, I’m at interested on seeing how yours turns out because the OEM one is way too tall.

 

[pixlpush]

Whatever height and shape you end up with make sure the front camera isn’t obstructed. It’s got a very wide angle lens and is right below the BRONCO text. I’m convinced that’s why the stock bar comes up so high. If you don’t have a front camera or don’t care no worries. I was surprised when I mounted fog lights on the factory bar that they fall into the cameras field of view.

 

[Frenchy906]

Whatever height and shape you end up with make sure the front camera isn’t obstructed. It’s got a very wide angle lens and is right below the BRONCO text. I’m convinced that’s why the stock bar comes up so high. If you don’t have a front camera or don’t care no worries. I was surprised when I mounted fog lights that on the factory bar that they fall into the cameras field of view.

Ya, that’s what my main curiosity is going to be. I can imagine that’s why the Sasquatch bar is so high, and if that’s the case, then I’ll go that high. But I can guarantee it’s not going to cost me $2000 to build one like the OEM one is.

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