What to Use

• Nerf bars are made using steel tubing which is shaped into a "u". Hollow steel tubing made of aluminum or steel is the most common material. This is shaped with bending bars. A heat source is also used. A blow torch or heat gun raises the temperature of the metal to assist in the bend. Finally, buckles are welded to the bar using a MIG welder. Nylon webbing is used for the platform of the Nerf bar.
  
  

Design

• Nerf bars are designed to match the size of the ATV. The Nerf bars extend from chassis frame of the ATV. A solid attaching point must be located on the bike. Many ATVs have accessible areas near the foot pegs where the bars are installed, so to design your Nerf bars these points must be located.
  
  Make your measurements carefully then create a template from cardboard or wood to be exact. During the construction of the bars, check to ensure that they properly fit your ATV by holding them up to the bike on the attachment points after each bend. This will ensure the fit is perfect.
  
  

Construction

• Begin by cutting am ample length of steel tubing that is longer than the length needed. The ends of the bars will be trimmed to meet the exact shape and size for your bike. The most important distance is the outside of the bar as this part may not be cut once the bend is made. To build the bars, the tube is set into the bender at the point of the first corner. Heat is applied and then the metal tubing is bent. After it cools the buckles are welded to the bars and the webbing is threaded through them.