I was able to borrow a JD2 tube bender from a coworker, and decided to make my own bumpers. Here are some photos from the front bumper build:
Finished product
Top main tube was 6 bends on 1 plane
Checking the angles
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Wrap-around frame mount and lower cross tube. Everything was templated with cardboard and cut with an angle grinder. Super high tech.
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Tied in to the frame horns
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Gusseting the frame mount
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More strength
Figuring out the angles for the mid tube. This one had 4 bends on 1 plane then 2 offset bends. I messed up the first time I tried this by offsetting one bend up and one bend down. Lesson learned.
Starting to look like a bumper
Made a fully boxed winch plate and tied it into the mid tube and lower support tubes
Working on the hoops. This is a very happy face after messing up 2 side tubes trying to get the bends and notches right. I think this photo was taken at like 1am. My neighbors love me...
Tube work done and it fit up nicely
Dimple died lower plates (14ga) and license plate tabs
16ga filler plate up top
Ready for paint. I added side support tubes from the frame mounts out to the mid tube. This made it a lot stronger and virtually eliminated any wobbling while driving (which was minimal to begin with). It'll also help keep things rigid when I'm up against a rock with the bumper.
Painted with VHT Roll Bar and Chassis Epoxy Paint (satin)
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2003 4Runner SR5, V8, 4WD
A few mods...
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