4x4Labs DIY Bumper Build

S

sbechtold

New member
Picked up a 4x4labs rear bumper for my sons 04 4Runner. Used this as an opportunity to teach him how to weld, use the plasma and do some basic fabrication.

Drove to 4x4labs and picked up a couple of bumpers. Also going to build front and rear for my 70 series land cruiser. Here is the pile of bumper parts.

IMG_20161218_125105_zpsegffzvbw.jpg~original


After chopping off the rear frame cross member... we start fitting the bumper base...

IMG_20161224_180731_650_zpszdk7zysz.jpg~original


Started welding the bumper together and got it all cleaned up...

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Decided to personalize the bumper a little by adding some dimples to the rear section.

IMG_20161228_133418_zps1x27vomh.jpg~original

IMG_20161228_151426_zps1zgjwvzj.jpg~original


Got the base all welded and cleaned up...

IMG_20161229_153210_zpssr7g1l7k.jpg~original


Then started on the swingout... used a synergy latch and hinge.

IMG_20161230_172216_zpsfywskbmo.jpg~original


Bentup some 1.75" tube for the tire carrier...

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Swing out mostly finished...

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Tried to keep the tire nice and tight (and low) to the rear end...

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Here's the final bumper before powdercoating. Used a 3/8" piece of steel for the tire mount. There is also a 1/4" gusset on the backside fo the tire mount to help stabilize it.

IMG_20170102_163500_zpss7nje7jy.jpg~original


Here is a closeup if the latch. These Synergy latches are awesome for bumping bumpers.

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Had the bumper powdercoated in crinkle flat black...

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The final product....

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My son did a lot of the work... turned out pretty good for his first real welding project.
 
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Nice! Looks like it could be a great starting point if one wanted to make a "custom" unit that didn't replace the sides of the bumper up to the taillights. I saw something like that on a 200 series that Slee built a while back, and I've wanted that for mine ever since. I know it'd require trimming the sides off the bumper, but I think that'd be worth it.
 
Can't wait to be teaching my boy all these modding skills! I'm liking the flush hitch action, did you(your son) actually weld a reciever behind the bumper, I see grinding on the face so I'm guessing yes? Access to the pin easy?
 
Thanks for the nice comments everyone...

unevolved said:
Nice! Looks like it could be a great starting point if one wanted to make a "custom" unit that didn't replace the sides of the bumper up to the taillights. I saw something like that on a 200 series that Slee built a while back, and I've wanted that for mine ever since. I know it'd require trimming the sides off the bumper, but I think that'd be worth it.
Click to expand...

We thought about trimming the side down and capping them, then trimming the plastic bumper to fit. But, my son decided he liked the taller side, so that's what he got. :) There are a bunch of options with this bumper.

FrenchToasty said:
Can't wait to be teaching my boy all these modding skills! I'm liking the flush hitch action, did you(your son) actually weld a reciever behind the bumper, I see grinding on the face so I'm guessing yes? Access to the pin easy?
Click to expand...

There is a piece of square tube that runs the width of the bumper in between the frame rails. The square receiver tube is welded to the backside of the bumper and the square tube. There are also a few gussets that help strengthen the entire hitch mounting system. The pin is right up behind the bumper face and pretty easy to get to. There are also places to connect your trailer chains to under the bumper. We remounted the OEM electrical connector under the bumper but up out of the way.
 
Awesome job and even more awesome that you are teaching your kid how to actually build something.

That's the exact bumper I'm thinking about building as well.

One more question though, in one of those pictures there's an FJ with what looks like a solid front axle swap. If so, do you have a build thread on it?
 
gm350reratliff said:
Awesome job and even more awesome that you are teaching your kid how to actually build something.

That's the exact bumper I'm thinking about building as well.

One more question though, in one of those pictures there's an FJ with what looks like a solid front axle swap. If so, do you have a build thread on it?
Click to expand...

Thank you... It was a lot of fun teaching him. The build thread for the FJC is here.
 
Nice touch you did there to make just a little different look.

Notice the swing arm housing looks a little different also, even has a zerks fitting added.
That's a lot of grease to be put in to fill at first.

Great looking rides altogether.
 
having fun said:
Nice touch you did there to make just a little different look.

Notice the swing arm housing looks a little different also, even has a zerks fitting added.
That's a lot of grease to be put in to fill at first.

Great looking rides altogether.
Click to expand...

Thanks...! Yeah that zirk is a little silly if you ask me. No one is going to fill the hinge with grease. We packed the bearings by hand and put a light coat of grease on the spindle before installing and called it good. :) Let's be honest... how much wear and tear will those bearings experience... my guess based on using those hinges for the past handful of years, is none.
 
sbechtold said:
Thanks...! Yeah that zirk is a little silly if you ask me. No one is going to fill the hinge with grease. We packed the bearings by hand and put a light coat of grease on the spindle before installing and called it good. :) Let's be honest... how much wear and tear will those bearings experience... my guess based on using those hinges for the past handful of years, is none.
Click to expand...

Actually you would be surprised. I had one on my rear bumper on my Jeep and I would grease it every 6 months to a year. it sits outside and the moisture can affect the grease more than just the wear and tear. I would purge the grease till I saw fresh come out of a hole on the bottom of the outer sleeve that I drilled. the spindle had the zerk and the grease came out of a couple of holes in the top bearing from the inside out, similar to trailer spindles.

It made a difference in how easy it was to open...
 
I know that is a smaller tire, but with that synergy latch do you see much bouncing or shaking when driving bumpy roads? I have tried clamps and a thru bolt but with a heavy 37" Toyota and bead locks I still get shaking.
 
philromero215 said:
I know that is a smaller tire, but with that synergy latch do you see much bouncing or shaking when driving bumpy roads? I have tried clamps and a thru bolt but with a heavy 37" Toyota and bead locks I still get shaking.
Click to expand...

Haven't had this one off-road yet, but driving around town or on the freeway the tire stays put. No shaking. You can't see any movement at all.
 
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