Powder coating is used the various parts and this coating adds to the thickness of the parts. When you go to slide one piece into another, the additional powder coating can, and usually does, cause a slight clearance issue. I didn't ask Jeff if he usually has someone run a drum sander around the inside of the tubing or not, but mine were already cleaned up when I got ready to put them together. You can see that the coating is cleaned away and will allow for an easy fit.
A few minutes were spent putting the pieces and parts together on the floor. I left the bolts loose so the sports bar could be shifted around and more easily positioned once it was placed into the tub.
Mike helped lift the sports bar into the Jeep and left me to finish up the rest of the install. He mentioned that easy access to the back dash area could be obtained by removing the speakers. OK....he talked me into it. The speakers came out and I recycled the mounting hardware that my old setup had used.
After I got everything lined up and the remaining mounting bolts loosely started in their holes, I began the final tightening process. Upon Mike's recommendation, I left the upper mounting (the ones that tie the sports cage into the factory roll bar) until last. I used them to put a little tension on the sports bar and caused it to be pulled to the rear just a bit as the four - bolts were tightened. I then checked the windshield frame clearance and it was fine. It did not touch the sports bar.
For those that may be wondering, the low profile dash bar that was also installed does obstruct some of the air flow from the defroster vents. After the windshield was back in position and bolted into place, I kicked on the defroster and turned up the fan a bit. I had good air flow at the top of the windshield. I see no issues for the folks who need winter defrosters in order to see out of their frosty windshield.
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