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.

 

[Iamcanadian]

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.

Do you happen to have a pic of your lights mounted on that bar?

 

[pixlpush]

Do you happen to have a pic of your lights mounted on that bar?

Sure, here’s a couple and what the front camera view looks like with them in it. Not really intrusive but I was surprised they showed up in The front camera view at all.

 

[Iamcanadian]

Sure, here’s a couple and what the front camera view looks like with them in it. Not really intrusive but I was surprised they showed up in The front camera view at all.

Thank you. I have four auxbeam 4 in round pods that I want to install, two Amber, two clear. I was originally planning on roof mounting them between the roof rails but I I have a couple sets of mounts left over in my shipping container from my old truck but I never installed and they will fit the tubing on that bull bar perfectly. I'm tempted to go that route. You placed your lights exactly where I want to put two of mine I'm thinking the other two right on the other side of the tube at roughly the same height.

 

[wireman]

Sure, here’s a couple and what the front camera view looks like with them in it. Not really intrusive but I was surprised they showed up in The front camera view at all.

Lights look good. Not really intrusive at all. The bar shows more than I thought it would.

 

[hefler]

There is a guy in Brazil that is selling.
Maybe we can check the price or get more info

 

[Frenchy906]

There is a guy in Brazil that is selling.
Maybe we can check the price or get more info

I’d highly pass on that. It’s literally mounted to the front with two small bolts on each side with nothing behind it to support it.

Mine is going to replace the tow hooks and actually have something worth a damn to mount to.

 

[hefler]

looks like more cosmetic creation this one from BR

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