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Old 03-08-2019, 02:18 AM #16
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Quote:
Originally Posted by Hwy88-Taco View Post
Good to hear that this is normal and worth working around it. As for the 03-05 grill, when I read up on the headlight swap for those who want the projectors, I learned that if they don't swap the grill they will have a small triangle gap at the lower corners of the grill. It seems that that although the headlights will bolt up they aren't an exact fit.
With that comes the grill swap which leads to another issue, interference with the bumper. So it turns out that the headlight swap is actually a face lift. Regardless of all of that useless info, the 03-05 grill is around an inch shorter so it sounds like an option for us (as long as it doesn't have some other hidden issue). I was also wondering if there is an aftermarket grill that is a viable option as well but I haven't looked in to it yet.

As for the gapping, I too plan to make some adjustments with washers or some type of shim to even out the wings with the headlights. Maybe once I get it dialed I'll just weld them to the bumper mounting plate then grind it flush. I'm thinking around 1/4" on the top stud? But I'll play with that to get it right.
I've got an 03 grill that I need to remove - had the 06 sitting in my garage for a Satoshi and not getting completed for years now. Could be enough of a kick in the pants for me to take it off if you're interested in it. Shipping's less than simple/cheap though.
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Old 03-08-2019, 03:15 PM #17
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nice fix, i believe i met you there as well!
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Old 03-11-2019, 11:00 PM #18
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relocation ideas

So, I had some time to do some re-wiring and relocating of since the bumper was scheduled for coating. You probably have already figured out the solution to the issues with our bumper.
1. Relocation of the AC hardline. I removed it from the square white plastic bracket. I removed the bracket all together to utilize the mounting hole. I drilled a hole into the horizontal plane of the support arm big enough to run a zip tie through the front (where the white bracket once was) and out the top to fasten the AC line, fog light and light bar wiring. I simply rotated the ac hard line on top of the bracket which gave me enough room for the winch plate to clear 1/8".
2. I cut a 3" length of samco silicone hose and spliced it as directed by one of the awesome guys on this thread. I lined the hard line in two places. One, where the ac line makes contact with the support arm and where the ac line could bonk into the winch plate.
3. I also bent back the two black tabs that support the trans radiator. Just enough to give clearance. 1/4"-1/2".
4. I am going to use the right winch access port to unlatch the hood.
5. I contemplated buying a new 20" single row rigid industries light but couldn't justify it. Soooooo, I hogged out the opening to house my existing 3" double row R.I. then re welded the tabs back into place.
6. I dropped off my bumper off at WEST COAST POWDER COATING! They are located at 165 Mitchell Ave, South San Francisco, CA · (650) 871-0400 Ask for AJ. These guys are top notch. Very well priced and usually under a week out.
I will return to this guy for the skids, and sliders when they need it.
7. I relief cut the same way you did to accommodate the hood fitment. I wanted to keep it as close to the grill as would allow. My buddy suggested that I give more allowance for body and bumper articulation. As much as I would want 1/8" more material back, he is right. If you wheel you may need some allowance.
I hope this info was helpful. I will share pics tomorrow after I have everything mounted up. I hope you share your final pics too.
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Old 03-17-2019, 06:34 PM #19
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So the first Pelfreybilt bumper for the 4th Gen 4Runners was built on Brian's 4Runner (from Goose Gear), an 03-05 model.

The second one was made for the Total Chaos 4Runner, an 06-09, and THIS is where Tyler discovered the slight difference between the 03-05's 06-09's. Tyler chose to do exactly what you did to solve the issue.

There's also the little swoop downward on the front trim piece on the 06-09, whereas the 03-05 is just flat, but this isn't an issue since the bumper doesn't go back that far.

The angles and fitment on mine was never perfect, I tried washers as shims in combinations on all three of the forward facing studs, and I think I settled on the best fit being on the top studs on both sides, but still not perfect, but close enough.

For the hood release, I made it accessible by bending up the finger tab that used to hang below so that I could reach it through the grill. This has worked without issue since I got the bumper.

I don't run a winch, but I did have to finesse the AC line, Pelfrey used to supply a small bracket to relocate the mounting position of the line, which I used, and it doesn't interfere with the bumper.
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Old 03-23-2019, 03:13 PM #20
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Quote:
Originally Posted by 4RunAmok View Post

For the hood release, I made it accessible by bending up the finger tab that used to hang below so that I could reach it through the grill. This has worked without issue since I got the bumper.

I don't run a winch, but I did have to finesse the AC line, Pelfrey used to supply a small bracket to relocate the mounting position of the line, which I used, and it doesn't interfere with the bumper.

Awesome! Thanks for the tips.

More fab work to come for this. My PB project is on hold while I finish brainstorming additional features and finish my other project "Camping trailer" (stay tuned for that build thread). Both of these projects are 4Runner projects since the Runner is my tow rig and the trailer goes where the Runner goes.

As for the storm that consumes my brain, I'm heavily weighing the idea of adding a 2" receiver to the front of the PB bumper. I'm thinking I could weld a receiver tube directly under the winch mount plate. I could then either cover the square hole with the license plate (though I hate front plates) or shove some receiver plug in there. After checking the local fab shop, Harbor Freight, eTrailers site and of course The Amazon, I noticed a trend among receiver tubes and hitches. It seems that the 5/8" hole for the lock pin is within 2" of the reinforcing collar. With the angle of the lower plate (below the winch fairlead) I would either have to let the receiver stick out several inches to access the pin or recess it so far back that I'd have to open the hood to get to the pin.

So with that said, I think I've devised a plan (pics to follow soon). I'm going to fab up a hidden integrated lock pin (kind of like a dead bolt on a gate or a cane pole anchor). The pin will be a large "L" shape. With a couple of sleeves on the receiver tube welded to a gusset under the winch mount and then to the receiver tube on each side. The pin will be longer on one side so it can extend completely through and protrude through the opposing sleeve. From the top, I'll cut an elongated hole (just a bit longer than the length of the throw) for the "L" leg to extend up through the mounting plate. I can then either access the pin through the left side (existing) cutout in the front of the bumper or from the top with the hood open. I'll add some spring option (torsion, detent, leaf) to hold the pin in either position.

However, this mod will have to wait until the winch arrives so I don't create some interference with it. More fab work to come!

I'll add some pics later in the evening edition edit of this post, stay tuned.


Several evenings later... The evening edition edit is here.

I had to first sketch this idea out to, a) get it out of my brain, and b) see it on paper so my minds eye wasn't the only one enjoying this idea. Now that I can see it with my eyes I can scale it and work on the little details. ALL FEEDBACK IS WELCOME! So please, guys and gals, throw me your thoughts here so I can make sure that I cover all angles. Maybe you don't have a hitch on your winch bumper but maybe you have a front hitch and have a point to make so please throw your $.02 in. It's worth the investment.


Front & back sketch


Close up of the hitch itself



Top view of how I think the lock pin could work. Three options for a spring included.

Last edited by Hwy88-Taco; 03-29-2019 at 04:31 PM. Reason: add pics
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Old 03-23-2019, 05:20 PM #21
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I have an 05' 4Runner with the PB Aluminum front bumper. I also have a 06-09' grille that I have been wanting to swap but ran into the grille fitment issues with the bumper and just haven't made the cut yet (like you have) to make it fit. It indeed looks like you got the 03-05' version for sure. Thanks for showing the markings & cut for the newer grille, this will help me in my endeavours once I find the time to do the grille swap.

I also have slight fitment issues like others have stated. I have shimmed the top mounting point outward to try and correct the tilt that seems to be built into these bumpers. As others have stated it's a work in progress and could be better, but itsn't terrible. I installed my bumper solo and ended up with a small amount of left/right tilt but I think that's because I struggled holding it up (with winch pre-installed) while I tightened everything down. lol That was a struggle.

I "massaged" my A/C line but after 4 months or so of driving it rattled itself on the edge of the bumper and wore through my line. I have to replace the line ($$$$) and when it was re-installed I had it wrapped in rubber (as others have stated) and have not had any issues now in the last 1.5-2 years.

I explored the same powdercoating idea as you, but ended up going with paint as my top priority was getting it color matched. I had the paintshop ad a couple extra layers of both paint and clearcoat knowing that is it not quite as durable as powdercoating. That being said, over two years later and it's not rusting and still looks great except for the odd rock chip. Plus I can use my Toyota touch-up paint pen to dab any small chips.

This is mine, taken last week. Approx 40,000kms of year round driving and 2 years after having the bumper painted.

EDIT: you can see I still could use a little more forward tilt on the bumper angle as well. It's currently spaced forward on the top stud about 1/4"


_08I1131.jpg by Addison Rickaby, on Flickr
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Old 09-10-2020, 11:17 PM #22
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Elongated shakedown successful!

1.5 yrs later and the finished product has gone through the shakedown test successfully. By shakedown I mean 2K mi from The Bay to The Cascades and back. As well as a few Sierra weekends to boot. I’m very sorry for ditching you guys. You’ve all been so helpful and encouraging.

After I received the winch I revised my plan for the front receiver with a long threaded pin that comes in from the drivers side. Works perfectly and much less complicated that my initial plan. I reworked the release lever to the left of the initial position. Instead of the lever being under the grill it is now in the first pocket above the bumper.

I also mounted the cylinoid/switch pack remotely to the radiator support, though after thought, I don’t think it was necessary. It looks like there would have been plenty of clearance on top of the winch.

I followed your suggestions for massaging the a/c line also finessed the power steering lines on the side of the frame. 2.5Kmi (4-500mi 4low trails) No chaffing or rubbing of paint or lines (tires are a different story).

Rustoium truck bed coating on the back and Rustolium white on the front +2 coats of clear. There’s a few rock chips but I now can touch-up very easily.

Any questions just fire away. I took plent more pics and I’m happy to take more if you’re courios. Happy to help since y’all have been so helpful.
Attached Images
Pelfreybilt Winch Bumper woes...-5f8db3e2-b3f8-4a1d-819a-f2764d1236ef-jpg  Pelfreybilt Winch Bumper woes...-ee501261-f933-407a-bca8-2b08ba2447d3-jpg  Pelfreybilt Winch Bumper woes...-8dedee9a-0f3a-4bed-98f2-0dd9224324ef-jpg  Pelfreybilt Winch Bumper woes...-426c0974-cfca-46f2-bfc5-5a574728add0-jpg  Pelfreybilt Winch Bumper woes...-b0bc3e9a-c66a-41d3-9326-66c931d9a27e-jpg  Pelfreybilt Winch Bumper woes...-84fbe3af-58eb-4c4f-ab09-5a70268a0162-jpg  Pelfreybilt Winch Bumper woes...-63206d83-f4e7-4298-a1dd-4e39c780bae5-jpg  Pelfreybilt Winch Bumper woes...-8a948ff9-26e0-458f-be66-6b1510269054-jpg 

Last edited by Hwy88-Taco; 09-10-2020 at 11:35 PM. Reason: I felt like it?
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