That means the bar moves relative to the body, and some vehicles need a 25mm gap between bar and body. The Disco is particularly rigid and gets away with a 10mm gap. The winching capability needs to be tested too, with the most powerful winch the bar can take at maximum load (up a rocky hill, brakes on!), testing to see if anything breaks or deforms.
The final stage is tooling. Precision jigs need to be created, then it's time to get production going, the installation instructions written, the press releases out and Discovery 3 owners can enjoy the protection of a quality protective bullbar.
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