Overland-G Aluminum Body Armor Package

Overview

The exterior specification for the Momentum build: front bumper, rear bumper, rock sliders with steel mounts, and expedition roof rack — fabricated and specified together. Component geometry, material and finish are consistent across the set.

Specification

Front and rear bumpers use AL5083 outer sections at 6 mm and S235 steel winch shelves at 3 mm. The steel carries the recovery loads; the aluminium keeps the outer form light and proportionally aligned with the G-Class body. The front shelf accepts a single-motor or dual top-mounted motor winch. Recovery loops are integrated at both ends.

The rock sliders are AL5754 at 4 mm with dimple die rectangle pressings for section stiffness. Contact loads transfer through S235 steel mounts into the body structure — mount geometry determines effective load capacity.

The roof rack is aluminium throughout with five reinforcement beams across the mounting span for stiffness under load.

Related systems

• Conversion Kits
• Build Your Overland-G
• Engineering

Project note

Winch shelf configuration — single or dual motor — must be confirmed before the bumper goes into production. Finish options: raw aluminium, ground welds or powder-coated.