Toyota Hilux Custom Bullbar

The Brief

A fleet management company needed durable bullbars for their Hilux work vehicles operating in rural areas with livestock and wildlife hazards.

Constraints & Requirements

Must maintain airbag compatibility, not exceed 50kg weight, provision for Warn winch mount, integrated fog light recesses.

Our Solution

Designed and fabricated from 3mm mild steel plate and 50mm tubing, with integrated LED fog light recesses and a Warn winch cradle. The design maintains crumple zone geometry for airbag sensor compatibility. Finished in textured black powder coating for durability.

Project Gallery

Outcome

Fitted in one day per vehicle. The fleet manager ordered bullbars for all 12 fleet vehicles after the first fitment. Zero warranty issues reported after 18 months of daily rural use.