Crack in drivers side sheet metal...

[Narkhelek]

Yep, I have a crack in the same place too. Awesome. That sheet metal is super thin. My guess is I'll drill, weld, and maybe add some plate to that area. Or see what the FJ guys did to resolve a similar issue.

Let us know if you figure something out. I've been looking through the FJ forums and I haven't found any kind of consensus on what to do about it.

 

[joneseyyy]

I'm really not that freaked out about this...not a mission critical loadbearing component. This isn't a great development, and I don't want it to get worse, and I'll try to fix it, but I don't think I'll lose sleep over it and ill continue offroading in the meantime. I have no idea how long the crack has been there.

 

[joneseyyy]

Just talked to Ted Moncure (head TRD engineer) at the Summit. He, like me, was not alarmed and said the FJs with issues were much worse. He said to drill it, weld it, and if you're so inclined, tack a plate over it.

 

[mgrande]

Front bumper is mounted on some high strength steel, which should handle some 200lb extra weight. But the frame cross members don't seem to be high strength. I'm thinking maybe the frame got twisted because of uneven tow/hit?
View attachment 93701

I'm with you, I know the fj's had a problem but bumpers are mounted to the frame not the body. Doest make sense to me but I could be wrong. I would say its just from body flex, not a bumper. Unless the bumper wasn't mounted low enough to allow frame flex.

 

[MeBe4running]

bet he'd be worried if you had a TRD supercharger under the hood :evil:

Just kidding, thanks for the heads up. I wasn't to concerned however Im going to address it as suggested.

 

[joneseyyy]

bet he'd be worried if you had a TRD supercharger under the hood :evil:

Just kidding, thanks for the heads up. I wasn't to concerned however Im going to address it as suggested.

Speaking of that...we may or may not have done a "hot lap" in a supercharged TE with Ted...

 

[4ShoreRunner]

Just talked to Ted Moncure (head TRD engineer) at the Summit. He, like me, was not alarmed and said the FJs with issues were much worse. He said to drill it, weld it, and if you're so inclined, tack a plate over it.

While it doesn't seem like anything more than a minor inconvenience I'm wondering if this will sway more individuals over to bud built's winch plate if a real steel bumper isn't absolutely necessary wave

Also, is this happening to folks both with and without aftermarket skids? I know my shrockworks skids removed the frame braces in the front but I assumed the skid plate itself would be adding more rigidity to the frame anyway.

Speaking of that...we may or may not have done a "hot lap" in a supercharged TE with Ted...

Ummm....details? pictures?

 

[Ariervintend]

Scary!!

This look scary to say the least. As you mentioned it might be thin custom sheet metal. still this big a crack!!!!

 

[KCcarguy]

While it doesn't seem like anything more than a minor inconvenience I'm wondering if this will sway more individuals over to bud built's winch plate if a real steel bumper isn't absolutely necessary wave

It just convinced me! Although you do have to wonder if it's just happening to those with steel bumpers because you guys tend to wheel your trucks harder. Besides...as was mentioned before, I thought Toyota resolved the frame issues when they updated the chassis in '10?

 

[BlackWorksInc]

This is interesting... I run a SW on my 4th Gen and I haven't seen too much evidence of cracking; not that I was looking for it before. I probably need to adjust my gap because the bump slaps against the front body on hard flex every now and then. I wonder if this affects the 4th gens as well..

 

[Nachies]

Are there any more reports of cracking? An is it just limited to the 2010's?

 

[05Rrunner]

Are there any more reports of cracking? An is it just limited to the 2010's?

I believe its pretty limited to those with aftermarket bumpers and the front frame supports removed.

 

[Nachies]

I was minute’s way from pulling the trigger on a SW, I was actually on the phone with Mark when I saw this post. At this point, I am going to shy away.

However, like mgrande stated; this does not make any since with the bumper being attached to the frame. The only things the bumper will do is stiffen the frame. This has to be body flex.

Harper, do you have any issues with your Budbuilt set up? I know you use your runner and you have some weight up front.

 

[flyrv9]

Just wondered - are all these cracks all on the drivers side only?

 

[Keemonrunnin]

Question for those with the cracks. While you guys where offroading,did you guys hit your front bumpers going up anything or coming down off a ledge of some kind while reversing?
I have my front bumper off right now ready to install my SW bumper. As I was looking in the fender well and the front end where the bumper will mount to the frame. There is a rubber stopper/absorber which is connected to the frame a little bit behind the mount. This rubber stopper is also connected to the same area a little bit below where you guys have the stress cracks. Here is a pic of the rubber bumper/stopper. Maybe this can have a little insight of what's going on.

 

[Keemonrunnin]

In this pic you can see that the rubber stopper/absorber connects to another sheet metal then connects to the area of where the stress cracks are happening.

 

[joneseyyy]

I drilled the end of the crack on mine in early August. Hasn't spread and I've been wheeling a bunch with it. Crisis averted.

 

[Jeremy556]

Just noticed this morning. Stock front bumper.
Haven't looked real closely, but it is right behind the battery. Wondering if my heavy ass boat battery might have something to do with it.

 

[SOcalTRAIL]

I had one of these on my passenger side way early on in my build, pre-armor or anything heavy. I actually noticed it when I was doing my suspension install and did the whole drill and grind operation on it. Its a combination of thin and apparently work hardened sheet metal, vibrations, flexing and a rough edge. In the aerospace industry we see these types of cracks emerge on parts with nicks or rough spots in the finished edge. It creates a starting point for the crack, I could get into technical details if anyone cares to hear...