Side steps/nerf bar steps

[rgunlock]

Need some help on ideas for fabricating a rear mount for nerf bars to go on a 78 GMC K15. This truck has saddle mount gas tanks. Got some universal nerf bar/steps from Dee Zee that were supposed to fit my truck. They state that some fabrication may be needed, but the mounts that shipped don't even come close. I haven't found any others more specific to this model truck. In order to get the step low enough to clear the gas tank, I only have two bolt holes into the frame up front, and as you can see from the picture, the rear mount will be 9-10 inches below the frame due to the step up in the frame.

I've done the google search on this site and in general and I'm not coming up with any good solutions. I'm not sold on these particular nerf bars even though I bought them, so alternative ideas would be appreciated. I don't think that the little steps that screw into the inner rocker will support my weight for long, so I need something frame mounted that can deal with my saddle tanks that cover the frame halfway up the cab. I can weld well enough, so pictures of how you've dealt with this will be a huge help.

[rgunlock]

Well, lack of responses probably means nobody bothers with these since they are only for sissies But, I'm guessing that there are other old farts with wives out there like me that can use a step like this. Maybe lack of response meant few others have tried to mount these? Any case, I've come up with a solution that I think I'm going to be happy enough with. Biggest challenge was the rear mount because the step has to clear under the saddle tank. I bought a 12x12" piece of 1/4" plate from Lowes that will be enough for brackets for both sides, plus a 4' piece of 1" square tube to use as a brace as well as some grade 8 3/8" hardware for mounting. Ok, also a fresh set of metal blades for the sabre saw and a new set of drill bits! This first picture is the rear driver side mounting setup.

The drop bracket that the bar mounting hardware attaches to was cut from the 1/4" steel. I used some 10 gauge to make the plate that bolts into existing holes on the bottom of the rear cab mount cross member. The 1" tube bracing is definitely necessary to stiffen things up. Also that diagonal brace isn't a straight lineup, so cutting and tuning of funky angles is necessary.

[rgunlock]

Couple other views of the rear mount. This will all come off for finish welding (and cleaning up my crappy tack welds) and paint. I also plan to round off the bottom of the brackets to match the radius of the bar. The angle bolted to the bottom of the frame actually came with the bar hardware, but had to be trimmed to clear the bolts below it. I ended up drilling out two existing rivets - one that was the lower front rivet on the cab mount cross member, and the other the bottom rivet for a factory exhaust hanger bracket. Otherwise, this rear mount only needed 2 new holes in the frame.

[rgunlock]

The front mount was much less work, but not a piece of cake either. It needed to be lower than ideal to keep the bar level given the drop to allow for the saddle tank. Only the top 2 bolt holes in the provided bracket lined up on the frame, so additional bracing was necessary. Ended up using a strip of 10 gauge with a gusset welded to the back of the original mounting bracket. This extra bracing bolts into a new hole on the bottom of the transfer case cross member. Both front and back mounting brackets are now extremely solid, which they need to be to handle my 235ish weight

[rgunlock]

Couple shots where I test-fit the tank to make sure I left enough room. I think this is going to work well and look pretty good once I touch things up. If there is any interest, I can provide more detailed pictures or measurements when I pull it back out to do the finish up.

[68panelman]

That's great work you did there, I've been following other threads on these but they are more the rock crawler style, Out here all we have is sand, so I'm opting for the step style like yours.

[rgunlock]

Hope the ideas help 68panelman. Here are some finished pictures of the mounting brackets.

[rgunlock]

And a couple shots of them mounted.

[Aussie Ol' Blue]

Love your work. Management is only 5' tall and finds it a bit of a climb up.
Inspired by your project I'm going to see what I can work out for mine.

[rgunlock]

Wow, thanks! Hope this helps you out.

[MTCK]

Nice work, Rick! I've been debating how to do some sort of steps with the saddle tanks on a variety of these trucks. I think you found a good solution.