03 4th Gen Hybrid Bumper

[Skrrt]

Hello all I was just wanting to show off a project that has finally come to fruition on my 03 4runner. In the summer I was looking to buy a bumper for this thing and really fell in love with the Tacoma hybrid bumper that Pelfrybuilt used to make. I scoured the internet to find one to buy and realize their was none and my wallet was a bit thin. The only hybrid style I had ever seen was [MENTION=130999]Inv4drZm[/MENTION] . I am a senior in high school and they have a welding program that I decided to join and this turned into my year long project. I designed the whole thing in cad and learned to weld over the whole year. Long story short hope y'all like it. If you have any questions on the build just drop them below.
I plan to powdercoat it black this week as well.

 

[Skrrt]

This is the plate that I CNC cut then bent on a press break

 

[Terminator03]

That looks awesome! I might suggest welding in some type of mesh material into the triangular areas just to fill in the side areas a bit, but other than that (which is just personal taste), it looks fantastic. I’d love to do something similar, but in aluminum plate to keep it lightweight. I love the Coastal weld together kit in aluminum, but that tag is way higher than I’d want to spend, especially considering I don’t have a TIG welder so I’d either have to pay someone to weld it, or spend the money to buy another welder.

 

[Skrrt]

That looks awesome! I might suggest welding in some type of mesh material into the triangular areas just to fill in the side areas a bit, but other than that (which is just personal taste), it looks fantastic. I’d love to do something similar, but in aluminum plate to keep it lightweight. I love the Coastal weld together kit in aluminum, but that tag is way higher than I’d want to spend, especially considering I don’t have a TIG welder so I’d either have to pay someone to weld it, or spend the money to buy another welder.

Thanks. Ya I thoigh about covering those areas up with somthing. I have seen that been done in the past, but I kind of like the exoskeleton look. I plan on filling those left and right gaps with a couple pods that I bought. I also would have loved to do it out of aluminum because this thing weighs a solid 110. I also have not learned tig yet but am soon. In the future I would like to get like a multimatic so I can do almost anything fab wise.

 

[Formidable]

Looks great and good of you to take this on while in high school. Learning these skills early on opens the door for business opportunity later.

 

[JVC8790]

Looks killer! I love these hybrid tube bumpers over the boxy bumpers most companies make.

Nice work!

 

[doofenshmirtz]

Very nice! Glad to see schools that still have these programs out there.

It's awesome as-is for sure. If you did want to go down the road of filling in those corners, a wire grid could fill that triangular gap while still keeping the exoskeleton look and provide some protection from debris. Something like some .120" wire in a 1-1.5" grid square/rectangle, then form to match the tube. Mark the trim-off areas, grind them off, then weld into place. ...This makes me want to fab a bumper at work.

As far as powdercoating, black mini tex is a great choice if you aren't sure. Smoother than black wrinkle or bed liner, but rough and durable like those. More like a sandpaper coating.

 

[Inv4drZm]

I disagree with the mesh idea, looks way cleaner without. Throw in dirt cheap LED pods like I did and it'll look perfect. I bolted them through an existing hole back in the body. No fab work needed. Can't remember if I had to remove the windshield washer bottle to mount them though.

Anyway, great job with it, looks sick!

 

[Skrrt]

Finally got this thing painted, decided to go with linex I love how it turned out.

 

[Formidable]

Looks mean! Great job

Finally got this thing painted, decided to go with linex I love how it turned out.

 

[milo88]

Looks really good. I was wondering if you ever had any problems with this design. I'm thinking about doing a very similar idea with the tube style sides for the bumper. Any issues with leaving the reservoirs exposed?