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Old 09-15-2019, 08:51 AM #1
Last Man Standing Last Man Standing is offline
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3rd. Gen passenger Side Bumper Replacement

Morning All,

Thought I would chime in on the progress of the RH side bumper replacement that is over the exhaust tail pipe. Living in the rust belt this bumper rots out where snow and salt accumulate in the rear curved area. " See Pic Below "

First off, lets start from the beginning and touched base with Olathe Toyota for a replacement part, but dues to the cost ( $200 ) delivered I went with an aftermarket one off Ebay for $40 delivered, which was primed, so needed to purchase paint and used 3 / 4 coats each base color and clear coat and a can of undercoating.

Waiting on polisher I ordered ( Griot's G9 w/5" pad system ) and using the Maguiar3rd. Gen passenger Side Bumper Replacement-dsc_0061-jpg

3rd. Gen passenger Side Bumper Replacement-dsc_0062-jpg's fine grit polish and Show Car Glaze to bring it up to factory look?
Well, at least I hope to, will update as progress continues.

Back to the old bumper removal, dam tough in these parts as all bolts have rusted solid. Used PB blaster over night and a torch to remove 2 of the 3 holding bolts. One remains a problem that holds the upper part of the bumper near the tire ( see pic ). The bracket that this attaches to is secured at one spot allowing the whole thing to twist as I try to remove this bolt.
Looks like I will need to take the recip saw and cut the nut off as that part is attached to the bumper so no harm to the bracket, I hope?

I will chime in as the job progresses.
Note! I will add the picture of the offending bolt as the upload is only allowing 2 pictures?

LMS
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Old 09-15-2019, 08:52 AM #2
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This is the picture of the bolt that will not come out due to weak bracket!

LMS
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Last edited by Last Man Standing; 09-15-2019 at 09:34 AM.
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Old 09-15-2019, 09:04 AM #3
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If it will fit, an angle grinder would probably have a cleaner, more precise cut.
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Old 09-15-2019, 10:11 AM #4
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I second the angle grinder. With a cutoff wheel. Sawzall will likely grab and bend metal. Just watch where the sparks go.
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Old 09-15-2019, 10:42 AM #5
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Well, there was one more bolt I had forgot to mention in the upper portion close to the plastic guard on top of the back bumper section. I had to remove the bumper guard and it was a good thing as I needed to clean up rust under it and apply Fluid Film to that area.

Note! I did not notice nor did the parts dept. suggest ordering the square plastic insert into the top of the side bumper but the old one was still somewhat intact so I reused it as the plastic shroud requires it to snap into.

PS: I did end up using the sawszall to remove the nut and cutting oil to help the blade do it's job without getting snagged!.
LMS
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Old 09-15-2019, 11:11 AM #6
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Yes be very careful with sawzall. Mostly they stick and shake the crap out of the steel. You can do more damage then good with those. Cut off wheels and angle cutoff wheels are the way to go. Mostly when the side bumpers rot, the rear is super close as well. Maybe you will luck out but I am never that lucky. I always paint the inside of the bumper with 2 heavy coats of rustoleum then when back on. Super soak it with fluid film to keep it from rotting out. :]

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Old 09-22-2019, 09:34 AM #7
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Quote:
Originally Posted by brillo_76 View Post
Yes be very careful with sawzall. Mostly they stick and shake the crap out of the steel. You can do more damage then good with those. Cut off wheels and angle cutoff wheels are the way to go. Mostly when the side bumpers rot, the rear is super close as well. Maybe you will luck out but I am never that lucky. I always paint the inside of the bumper with 2 heavy coats of rustoleum then when back on. Super soak it with fluid film to keep it from rotting out. :]

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Well, for the first attempt not bad, it won't win any awards that's for sure.
Need to see what additional buffing pastes or waxes need to be done to get a
more mirror like finish? The aftermarket needed some shimming and one hole routed out a bit, but for the $40 cost a small price to pay imo. LMS
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Old 09-22-2019, 12:40 PM #8
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I am working on a mod to stop these side bumpers from rotting out. Once I am happy with the results. I will post them to the forum. :]

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Old 09-22-2019, 03:57 PM #9
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Quote:
Originally Posted by brillo_76 View Post
I am working on a mod to stop these side bumpers from rotting out. Once I am happy with the results. I will post them to the forum. :]

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Yo Brother Brillo,

I got another thought you could consider since your so proficient at metal work and welding. The rocker panel at the front of the passenger side door is rotting out at the fender flare point due to a open area to the tire well

Any thoughts or suggestions would be appreciated.

LMS
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Old 09-29-2019, 08:42 PM #10
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Quote:
Originally Posted by Last Man Standing View Post
Yo Brother Brillo,



I got another thought you could consider since your so proficient at metal work and welding. The rocker panel at the front of the passenger side door is rotting out at the fender flare point due to a open area to the tire well



Any thoughts or suggestions would be appreciated.



LMS
My tetanus 1 dosent even have that section left. I have to fabricate new ones out of steel. I have the outer rockers for it. I even have the 16 gauge square tube I am going to weld in the rocker. It's the inner rockers I am waiting to arrive as mine have turned into oxide.

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