Aluminum vs. Steel Nerf Bars: Pros and Cons

When upgrading your truck or SUV, choosing the right Nerf bars is a crucial decision. These step bars, including popular options like oval Nerf bars, not only add style to your vehicle but also offer functional benefits like easier cab entry and exit, protection for rocker panels, and improved safety. Two of the most popular materials for Nerf bars are aluminum and steel, both of which come with their own pros and cons. In this guide, we’ll take a deep dive into the advantages and disadvantages of aluminum and steel Nerf bars, helping you make an informed choice for your vehicle.

Aluminum Nerf Bars

Pros

One of the biggest advantages of aluminum Nerf bars is their lightweight design. Aluminum is significantly lighter than steel, which means installing aluminum Nerf bars will not add unnecessary weight to your vehicle. This is especially important if you’re conscious about fuel efficiency, as extra weight can slightly reduce your vehicle’s gas mileage. The lighter nature of aluminum also makes installation easier and more manageable.

Aluminum’s natural resistance to rust and corrosion makes it an excellent choice for areas prone to wet or salty conditions. If you live in a region where rain, snow, or salted roads are common, aluminum Nerf bars offer superior protection against corrosion compared to steel. This resistance to rust makes aluminum Nerf bars ideal for those who want a durable option without the worry of long-term wear and tear.

Aluminum Nerf bars often feature a polished, shiny appearance that can give your vehicle a sleek and modern look. Whether you prefer a polished finish or a matte one, there are various styles to match your vehicle’s aesthetics. They maintain their look for years without fading, adding a premium touch to your vehicle.

Due to its corrosion resistance, aluminum requires less maintenance compared to steel. You won’t need to frequently treat or repaint aluminum Nerf bars; they generally won’t rust or stain. A simple wash will keep them looking as good as new.

Cons 

While aluminum is resistant to rust, it is generally less durable than steel in terms of impact resistance. If you frequently drive off-road or in rugged conditions where your Nerf bars can potentially get damaged, aluminum may be more prone to dents and bending. The lighter material does not provide the same strength and rigidity that steel does.

Aluminum Nerf bars tend to be more expensive than their steel counterparts. While the long-term durability and rust resistance might justify the cost for some, the initial investment is typically higher.

Steel Nerf Bars

Pros 

Steel Nerf bars are known for their superior strength and durability. They can handle rough terrains and take a beating without bending, making them ideal for off-road enthusiasts or heavy-duty use. Steel offers excellent protection for your vehicle’s rocker panels and can withstand greater impacts than aluminum. Steel is often the better choice if durability and ruggedness are your primary concerns.

Steel Nerf bars are generally more affordable than aluminum ones, making them a budget-friendly option. While there are various grades of steel Nerf bars (ranging from carbon steel to stainless steel), even the higher-end options often come at a lower cost than comparable aluminum bars.

Steel Nerf bars come in a variety of finishes, including powder-coated black, polished, or chrome. This allows you to customize the look of your Nerf bars to match your vehicle’s style. Powder-coated finishes enhance the appearance of the Nerf bars and add a layer of corrosion resistance.

Many steel Nerf bars, like the Westin Nerf Bars, are built with a solid 1-piece, fully-welded design. This adds to their strength and ensures they remain sturdy under heavy use. The one-piece construction also makes for a cleaner look and simplifies installation.

Cons 

Steel Nerf bars are significantly heavier than aluminum, which can have a minor impact on your vehicle’s fuel efficiency. The extra weight also makes installation a bit more difficult, often requiring additional hands or tools. If you’re looking for a lightweight option, steel may not be the ideal choice.

Steel is more susceptible to rust and corrosion than aluminum, particularly if you opt for lower-grade carbon steel without adequate protective coatings. Even powder-coated or painted steel Nerf bars can eventually chip or scratch, exposing the metal underneath to rust. Stainless steel options are much more corrosion-resistant but can come with a higher price tag.

Higher Maintenance Maintaining steel Nerf bars can require more effort than aluminum. You’ll need to check for chips or scratches in the coating and address any rust issues promptly to ensure long-term durability. Frequent maintenance and touch-ups may be necessary, especially in harsh weather conditions.

Which Is Right for You?

Choosing between aluminum and steel Nerf bars comes down to your priorities. If you’re looking for a lightweight, rust-resistant option with a modern appearance, aluminum Nerf bars may be the best fit. Their sleek finish, easy installation, and low maintenance make them a great option for those who prioritize aesthetics and corrosion resistance.

On the other hand, if durability and strength are your top concerns, steel Nerf bars are the way to go. They offer superior impact resistance, come at a lower price point, and provide excellent protection for your vehicle’s rocker panels. Remember that they require a bit more maintenance, and you may need to be vigilant about rust.

Ultimately, the decision between aluminum and steel Nerf bars depends on how and where you drive and your personal preferences for style, durability, and budget. Both materials have their merits, so choose the one that best aligns with your needs and lifestyle.