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Old 10-15-2015, 07:43 PM #1
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DIY Bumper Build (PICS)
EDIT: I uploaded the finished product pics into this first post.





Decided to build a bumper. So far I’ve done a mock up out of cardboard.

It will be out of 1/8” because:
a) I already have that size on hand;
b) it’s more for looks, I don’t off-road that often;
c) slightly lighter
d) I’ll use several gussets

I’ll drill holes in the skid plate for air flow. I may throw a light bar in the canter and a single hoop on the top.

What do you think of the mock-up? I like the look but anything I should change structurally?




Last edited by jahmes143; 11-23-2015 at 03:31 PM.
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Old 10-15-2015, 08:00 PM #2
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What's your plan to create it? Are you going to 3D model it, cut it on a plasma table, and weld it? It looks like a good functional design, just make sure your mounting points/tabs are strong.
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Old 10-15-2015, 11:24 PM #3
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I wish I had access to that stuff. I plan on hand cutting with a plasma (on a wheel so I can make pretty straight cuts. And circles), then welding. I'm sure there will be lots of grinding and a good bit of trial and error in the mix too.
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Old 10-16-2015, 12:13 AM #4
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I'd be concerned about how that cardboard will handle a deer or a head on crash.














Looks legit, I can't wait to see the outcome with steel. I wish I had the tools and the skills to pull off a bumper.
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Old 10-16-2015, 09:54 AM #5
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Quote:
Originally Posted by Drunner97 View Post
I'd be concerned about how that cardboard will handle a deer or a head on crash.

Looks legit, I can't wait to see the outcome with steel. I wish I had the tools and the skills to pull off a bumper.

I have the tools. Skills we shall see...
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Old 10-16-2015, 10:40 AM #6
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If it turns out good, maybe you could start a little side business or have Josh make them. Save some on shipping for us Florida folks.
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Old 10-16-2015, 10:51 AM #7
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Quote:
Originally Posted by S4TA View Post
If it turns out good, maybe you could start a little side business or have Josh make them. Save some on shipping for us Florida folks.
Who's Josh? Kinda new here and just getting to know folk.
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Old 10-16-2015, 10:58 AM #8
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Quote:
Originally Posted by jahmes143 View Post
Who's Josh? Kinda new here and just getting to know folk.
The legendary Josh Whitson. @Whitson Metalworks

He is located up in the panhandle. Does really good work and will hopefully be starting work on 4rth gen bumpers soon.
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Old 10-16-2015, 11:14 AM #9
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Quote:
Originally Posted by S4TA View Post
The legendary Josh Whitson. @Whitson Metalworks

He is located up in the panhandle. Does really good work and will hopefully be starting work on 4rth gen bumpers soon.
Thanks man, but my 4th gen plans kinda hinge on the 3rd gen stuff taking off and....it ain't. I've always wanted to do a plate bumper like this but as I'm sure jahmes143 can attest, doing what he's doing more than once isn't practical. You need some CNC cutting and bending equipment to produce a bumper repeatedly and get production time down to anything profitable.
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Old 10-16-2015, 11:30 AM #10
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Since my time is valued at $0/hour, I'm actually making a nice profit off myself .
You're right Josh, this isn't scale-able (or profitable) without big $$$ machinery for repetition, accuracy, and speed.
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Old 10-16-2015, 11:34 AM #11
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Quote:
Originally Posted by Whitson Metalworks View Post
Thanks man, but my 4th gen plans kinda hinge on the 3rd gen stuff taking off and....it ain't. I've always wanted to do a plate bumper like this but as I'm sure jahmes143 can attest, doing what he's doing more than once isn't practical. You need some CNC cutting and bending equipment to produce a bumper repeatedly and get production time down to anything profitable.
That's too bad that it isn't taking off. Maybe there will be more interest in the rear bumpers. I, for one, want to get some kind of hybrid swing arm tire carrier, but don't want to replace my whole bumper.

Excuse my ignorance on this subject. I don't know too much about metalworks. I am into woodworking, which does not apply to my 4Runner at all (wood bumper?).
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Old 10-16-2015, 03:20 PM #12
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Sweet! Can't wait to see your process and how you secure it. Will be great to see how it all works out. Looks as though it will look great just going off of the cardboard mockup.
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Old 10-19-2015, 10:01 AM #13
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Made some progress this weekend. The fit is good. Still need to incorporate some gussets for strength. Used about 1/2 to 2/3 of a 4x8 sheet.


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Old 10-19-2015, 12:13 PM #14
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Looking good. Really starting to think I should take some welding classes. I'd much rather DIY than buy and the more I'm seeing around here the more it's pushing me towards learning to weld.
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Old 10-19-2015, 01:51 PM #15
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Quote:
Originally Posted by Drunner97 View Post
Looking good. Really starting to think I should take some welding classes. I'd much rather DIY than buy and the more I'm seeing around here the more it's pushing me towards learning to weld.

I've been thinking the exact same thing. Is the university of YouTube any good for the DIYer?
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