NC Fab approached me to develop a custom bullbar for the Nissan GU Patrol based on the design of an 80 Series LandCruiser bullbar they had previously fabricated.
The original 80 Series bar had already been proven in the real world, but it existed primarily as a physical fabricated product. The first stage was to turn that existing design into an accurate digital CAD model so it could be reproduced using laser-cut and folded sheet metal.
From there, the challenge was to carry the same design language across to a completely different vehicle while maintaining the features and proportions that made the original bar work.
I started by 3D scanning the GU Patrol, capturing the front end, chassis mounting areas, grille, headlights, guards and surrounding bodywork.
The existing 80 Series bullbar was then digitised and used as the design reference. Rather than simply copying the original dimensions, I retained the key design cues and adapted the geometry to suit the Patrol's front-end shape and available space.
This allowed the new bullbar to retain the same overall character as the original NC Fab design while being properly developed around the GU Patrol.
The bullbar was designed as a sheet metal assembly using laser-cut and folded components.
A major focus was maintaining high clearance across the front of the vehicle while still providing a strong structure for off-road use. The design incorporates a substantial winch mounting structure along with strong recovery point attachments integrated into the front of the bar.
The individual components were designed with tab-and-slot features to help accurately locate the parts during assembly and make the welding process more straightforward.
With the design completed, I produced detailed CAD drawings for NC Fab covering the dimensions, component geometry and fold angles required to manufacture and assemble the bullbar.
Production-ready DXF files were also supplied for laser cutting, allowing the design to move directly from the digital model into fabrication.
The result was more than just a 3D model. The complete design package gave NC Fab the information and files needed to manufacture the bullbar themselves.
The finished design brings the proven styling and design cues of NC Fab's existing 80 Series bullbar across to the GU Patrol, while being developed specifically around the Patrol's geometry.
NC Fab is fabricating the bullbars themselves and plans to offer the design as a finished product. The project demonstrates how an existing
fabricated product can be 3D scanned, converted into a digital design and then adapted for another vehicle while retaining the original
design intent.
This project combined 3D scanning, reverse engineering, CAD development and design for manufacture to turn an existing physical bullbar into a production-ready digital design.
The completed package gives NC Fab a repeatable way to produce the bullbar using laser-cut and folded components, while providing a solid foundation for taking the design into production as a new product.