Converting Tube Bumper to Hybrid?

[Panman]

Hey, does anyone have thoughts or suggestions on turning a front tube bumper into a hybrid one? I scavenged an Addicted Offroad tube bumper off of a second 4Runner that was trashed, so it was cheap. But I i prefer plate bumpers, and how they don't leave as much of the front end exposed. Is it better to sell/trade it and get what I want, or is getting steel or aluminum plates welded on to it feasible/cost effective?

Alternatively, I would consider getting a welder and putting them on myself; but I have never welded (I have a very strong desire to learn). Would this be a feasible project to learn on? I know it wouldn't be load bearing, so my lack of skills would not be as much of an issue there, but possibly more so in the difficulty of angles, vertical welds, or something like that, perhaps?

Thanks in advance!:help:

 

[thatoneguygeoff]

One of the awesome things about fabricating is if you don't like it, cut it apart and start over!

 

[Panman]

One of the awesome things about fabricating is if you don't like it, cut it apart and start over!

Do you think this is a feasible/realistic first project?

 

[4Running Daily]

Do you think this is a feasible/realistic first project?

Yes, assuming you have the proper tools.

 

[D Farms]

I dont know about welding aluminum plates in, but welding steel plates in would make a super strong bumper.

 

[AssBurns]

It sounds like a good first project. Since you are already starting with a well built bumper and just adding plate to it. What could possibly go wrong if you mess up? Just like thatoneguygeoff said, if you mess up just cut it out and try again. We've all been there and had to do it at some point.
Also plating it with aluminum would be pretty damn cool. Since the bumper is already solid you wouldn't need 1/4" plate to make it structural. But if you plan on bashing it hard from Offroading hard you may want to do 1/4" aluminum or 3/16" steel plate. Just remember steel is heavy and aluminum is expensive. If you were to do aluminum I'd weld some trick tabs behind the plate and countersink some Allen bolts in there to keep it a really flush fit.

 

[rolling7high]

I say do it! Get yourself a good welder, use the gas and not the flux core. I bought a 4runner and a few months later ended buying a welder. Make/buy yourself a good table. Place the bumper on the table and start piecing it together. I recommend welding the bumper on the table and not on the ground or 4runner. Its much easier to learn that way.

 

[thatoneguygeoff]

Yea it would be a good first project

 

[MandAtaco]

Do it! Get involved with with a local off road group and see if there are some welders there that can give you some tips. Watch lots of YouTube video's on techniques. Run down to your local metal shop and see if they have a scrap pile you can dig through. Get some junk steel and practice practice practice.

If you want to run aluminum inserts, another option would be to weld steel tabs onto the tubes of your bumper, and then make removable panels that bolt in and out off the tabs.

Something like this:

 

[Panman]

Thanks for the input everyone! Do you have any suggestions for a welder? I'm still in school, so it can't be crazy expensive. I don't want to go really cheap and have to replace it, so from what I've heard Hobart, Miller, or Lincoln are probably best quality-wise.

Also, cutting wise, what would be a good route? Oxygen and acetylene or go with a plasma cutter when I can afford it? Or just have my local fabrication shop CNC what I want?

Get involved with with a local off road group and see if there are some welders there that can give you some tips.

What really sucks about were I go to school is that there is one (active) off road group, and it's a jeep group. On their website they literally have their one rule to join listed- own a Jeep; which, I don't. I'm still going to see if I can work my way in somehow, in spite of the rule.

And thanks for the picture, I need to try to find more pictures and find out what I really want to do. I'm leaning towards using steel because of the cost, and getting set up to weld is obviously going to have taken a good chunk of change out of my wallet already.

 

[csp]

An angle grinder with a cutoff wheel is the most cost effective way to cut accurately.

I have access to all kinds of cutting methods and still use the hell out of my Makita grinder with a cutoff wheel on it.

IMO, this isn't a beginner project if you want it to look good.

 

[AssBurns]

Lincoln welders are cheaper than Miller but Miller is a little bit better quality but if you are just getting a beginner welder any of the 3 you listed are good. 140's will do most stuff you need it to do but if you have the money a 180 is much better but you may need to get 230V added to your house if you don't already have it. I have a Miller 211 that runs on 120v or 230v but I always use 230v because I have it. Search Craigslist for a newer used one to save some money.
As for cutting I would start with an angle grinder with a cutoff wheel. I would save up for a plasma rather than oxy acetylene just because it's cleaner cuts, more simple to set up, and faster to start and stop between cuts. But you also are going to need a good air compressor to keep up with a plasma cutter so keep that in mind too.

 

[Panman]

An angle grinder with a cutoff wheel is the most cost effective way to cut accurately.

I have access to all kinds of cutting methods and still use the hell out of my Makita grinder with a cutoff wheel on it.

As for cutting I would start with an angle grinder with a cutoff wheel. I would save up for a plasma rather than oxy acetylene just because it's cleaner cuts, more simple to set up, and faster to start and stop between cuts. But you also are going to need a good air compressor to keep up with a plasma cutter so keep that in mind too.

I have no clue why using an angle grinder didn't occur to me. Just goes to show how much I have to learn.

 

[volkinator]

I have no clue why using an angle grinder didn't occur to me. Just goes to show how much I have to learn.

I've got a buddy that used a steel circular saw and built his front and rear bumper with it. Got a lot of flack for it, but seriously the cuts turned out amazing, and easy to keep straight.

 

[Panman]

After way to long, I got a welder (I actually got it last month, but had to get a part). I got an old Hobart Handler Genex 120. I'm excited to finally be able to start welding, I'll be practicing quite a bit before I touch the bumper, mostly non visible things. My first project will probably be a double battery tray. My dad also wants me to weld some disc golf baskets to make a small course on their property, since that's not very structural I'll probably do that early on too.

Thanks for the input, everyone!