Custom rear bumper

[yeti_4runner08]

Has anyone out there fabricated their own rear bumper? If so I have a lot of questions for you? But would love any input on what others think and maybe some expertise. Im a college student so I won't be able to start this project till the summer but I am planning now to make things go smooth when I get there. Would appreciate finding at least one person to talk to about this. Im more than stoked to get this project and yes I know I can just go buy one but I rather get the experience and joy that comes to making your own piece. Thanks.

 

[kernel.panik]

search through some of the build threads, quite a few have built their own, but names escape me.

You could also search:
enter this in the googles...
site:toyota-4Runner.org/3rd-gen-t4rs/ rear bumper

 

[KidVermicious]

Has anyone out there fabricated their own rear bumper? If so I have a lot of questions for you? But would love any input on what others think and maybe some expertise. Im a college student so I won't be able to start this project till the summer but I am planning now to make things go smooth when I get there. Would appreciate finding at least one person to talk to about this. Im more than stoked to get this project and yes I know I can just go buy one but I rather get the experience and joy that comes to making your own piece. Thanks.

I haven't made my own rear bumper yet, that's a lot of project for a guy that hasn't done any fabrication at all. I have made a couple smaller things, and I'm learning as I go.

You don't need a lot of tools, you can get by with an angle grinder, some clamps, and a welder, but it's got to be a good welder, and you've got to be a good welder. So that'd be my suggestion - get a good welder, and read a couple books on welding and watch some youtube videos so you've got a solid handle on welding theory, and then practice a bunch. Start by gluing scrap together, then cut apart your welds and see what your penetration is like. Then do some small projects, like welding up a cart for the welder or making a vise stand or something. Until you can repeatedly get good penetration and a consistent bead doing butt welds and lap joints on 1/4" plate, you really shouldn't be thinking about fabricating something you're going to attach to a vehicle that'll be sharing the road at 80 mph with other vehicles.

These'll get you started - the guy is a goofball, but watch anyway.
How to Weld, Part 1 - YouTube
How to Weld, Part 2 - Create Some Metal Wall Art! - YouTube

 

[dtc81]

I second what KidV says. Practice a whole lot on different thicknesses and welding at different angles. I built my tube bumper, and in my opinion, tube is a little trickier to work with at first than plate stuff. Practice making templates as well, then cutting out the shapes and welding it up. Prepping the steel at first correctly is a critical part.

 

[MStudt]

Has anyone out there fabricated their own rear bumper? If so I have a lot of questions for you? But would love any input on what others think and maybe some expertise. Im a college student so I won't be able to start this project till the summer but I am planning now to make things go smooth when I get there. Would appreciate finding at least one person to talk to about this. Im more than stoked to get this project and yes I know I can just go buy one but I rather get the experience and joy that comes to making your own piece. Thanks.

What questions are you looking to have answered? I'm going to build my rear bumper with a tire carrier, sliders, and most likely my front. The only reason I might not build my front bumper is due to the fact that Addicted Offroad's new bumper is so awesome. There are quite a few threads on here that can give you some input on where to start. If you don't have access to any brakes or benders, get ready to do a lot of cutting, welding, and grinding. My suggestion is to build one from cardboard first, so you can change things if needed.

It's not hard to make your own bends in plate, but you'll need a welder to finish. I've made several jeep bumpers before I became a 4runner fan. You'll have to mark your line and use a grinder to cut a slot in the metal, but not all the through. Once you cut through about half way (or more), you can use some adjustable wrenches to bend it. After you bend it you'll have to weld the slots up, and grind them smooth.

If you're looking into getting a welder, stay away from Harbor Freight for this one. Their welders are good for thin sheet work, but I wouldn't use them on anything else. My choice would be finding a used or new Hobart Handler 140 and get it up for gas. The 140 should be plenty for what you'll need it for. I have a used Lincoln 140 welder that works good, but I'd take a Hobart over this anytime. Miller welders of course are the best, and you'll pay for it. Look for a used one on Craiglist, and make sure you try it before you buy it. The technique to welding is not hard to pick up. The hard thing about welding is learning how to set you welder, and the speed at which you weld. These things will all come with practice.

 

[white_n_slow]

College student.

Do you have a garage? If so, does that garage have 220v power? Do you have a welder? If so, does that welder work on 3/16" steel or thicker? If so, do you know how to use it?

I see "college student" and I read "no resources." Lol, sorry if I'm wrong.

Plenty of people have built their own bumpers on this forum. Check some build threads for ideas. Some that come to mind: Dirtco, Full_Throttle, blcktpgsr. I know there are many more, but these are some of my favorites.

 

[JWaldz]

[MENTION=55891]Bandit Runner[/MENTION] comes to mind when doing cool steel projects..

 

[IBallEngineer]

I have built several bumpers, for a variety of vehicles. The first advice I'd give you from the start is it is usually not cheaper than buying one. But I do understand the desire to design and build it yourself, as well as the satisfaction that brings. So the 2nd bit of advice I'll offer is to keep it simple.

What sort of questions did you have?

 

[MStudt]

I have built several bumpers, for a variety of vehicles. The first advice I'd give you from the start is it is usually not cheaper than buying one.

I'd like to know how you came up with this? I would only agree with this statement if the OP doesn't have or have access to a welder. I could buy one from Addicted, and with shipping it would cost me $875. I can buy all the materials to build one similar to theirs for about $150. We'll call it $200 since I know I'll need something along the way.

 

[TCMach]

I'd like to know how you came up with this? I would only agree with this statement if the OP doesn't have or have access to a welder. I could buy one from Addicted, and with shipping it would cost me $875. I can buy all the materials to build one similar to theirs for about $150. We'll call it $200 since I know I'll need something along the way.

Time. For most of us our time is free but if you really think about it, a bumper is serious man hours. Design, cut, fit, tack, make changes, re- tack, final weld, clean up, prep, paint. Hell I had probably 10 hours in two sets of rcam skids and that's not even close to a bumper.

 

[IBallEngineer]

I'd like to know how you came up with this? I would only agree with this statement if the OP doesn't have or have access to a welder. I could buy one from Addicted, and with shipping it would cost me $875. I can buy all the materials to build one similar to theirs for about $150. We'll call it $200 since I know I'll need something along the way.

Well like I said, I've built several bumpers. I spend a lot more than $200 on materials. I'm not talking about 2 tubes welded together and calling it a bumper. I usually start with a full width piece of 3/16" or 1/4", and I have it bent in two or 3 spots. I use cut off wheels, grinding discs, chop saw blades, drill bits, die grinder accessories, taps, etc. When I am done I have it powdercoated. If it has a tire carrier there is a lot of hardware to buy as well. I've also taken a scrap piece of 2x6 tubing and made a jeep bumper with almost no expense at all. But usually I spend a lot, and invest 30 to 60 hours. When I figure out how to post a picture, I'll dig some out and 'splain.

 

[MStudt]

Time. For most of us our time is free but if you really think about it, a bumper is serious man hours. Design, cut, fit, tack, make changes, re- tack, final weld, clean up, prep, paint. Hell I had probably 10 hours in two sets of rcam skids and that's not even close to a bumper.

Sure, I can see the time and that is understandable. For me though, I wouldn't count that as money. My situation might be a little different considering it's not my dd. Mine can sit while I work on it as I have time.

Well like I said, I've built several bumpers. I spend a lot more than $200 on materials. I'm not talking about 2 tubes welded together and calling it a bumper. I usually start with a full width piece of 3/16" or 1/4", and I have it bent in two or 3 spots. I use cut off wheels, grinding discs, chop saw blades, drill bits, die grinder accessories, taps, etc. When I am done I have it powdercoated. If it has a tire carrier there is a lot of hardware to buy as well. I've also taken a scrap piece of 2x6 tubing and made a jeep bumper with almost no expense at all. But usually I spend a lot, and invest 30 to 60 hours. When I figure out how to post a picture, I'll dig some out and 'splain.

I'm not talking about building a double tube bumper like a lot of jeeps have. I've got a nice stack of 3/16" and 1/4" at the house, and I spent around $148 and some change on that material. One thing I never though of were grinding wheels and cut offs, and yes those will add up. You really don't save anything on the powder coat, since ARB is the only bumper that comes powder coated. My figure might be after after considering all the supplies, but I'd bet I'll still save more than $500 on the bumper (time not included). I completely realize there are numerous hours required in prefabbing, welding, cutting, grinding, and everything else.

 

[yeti_4runner08]

To everyone who has replied I cannot thank you enough for the info. I guess I missed out on some important details. I should have stated that I have a good welder being able to teach me and do the work. I actually have two welders at that but they have all needed equipment already at their house garage. They also have a pipe bender and basically any of equipment I will need. That is why Ill be doing it over the summer cause I will be back home to be able to use these resources. Planning all spring semester to get as ready as I can.

 

[MStudt]

To everyone who has replied I cannot thank you enough for the info. I guess I missed out on some important details. I should have stated that I have a good welder being able to teach me and do the work. I actually have two welders at that but they have all needed equipment already at their house garage. They also have a pipe bender and basically any of equipment I will need. That is why Ill be doing it over the summer cause I will be back home to be able to use these resources. Planning all spring semester to get as ready as I can.

If you have all these resources at your disposal, I'd build one. Read through some threads that show the process. There are a few good ones out there, and you can really get a feel for what needs to be done.

 

[yeti_4runner08]

I have built several bumpers, for a variety of vehicles. The first advice I'd give you from the start is it is usually not cheaper than buying one. But I do understand the desire to design and build it yourself, as well as the satisfaction that brings. So the 2nd bit of advice I'll offer is to keep it simple.

What sort of questions did you have?

I know I'll have way more questions as I go but I can start with a few.

Is there a specific type of steel I need to get?
Im doing a steel tube bumper for the most part but I figure Id be able to get my steel at home depot and hopefully be able to work there soon giving me a discount on it all. I am also going to need some plates as well as that is in the design I am sort of going off of.

Where do I start?
I know every project starts with a drawing to a mach up but is there anything specific that every steel project has to it that is a key step?

As for man hours, I understand that it will be A TON of work but say I get all my planning done and anything like that done, would my odds of getting it done over a summer be feasible. Of course I can't work on it 24/7 but my spare time Ill be on it.

As for that Ill leave with those questions for now. I plan on doing a full build thread when it gets closer.

 

[yeti_4runner08]

What questions are you looking to have answered? I'm going to build my rear bumper with a tire carrier, sliders, and most likely my front. The only reason I might not build my front bumper is due to the fact that Addicted Offroad's new bumper is so awesome. There are quite a few threads on here that can give you some input on where to start. If you don't have access to any brakes or benders, get ready to do a lot of cutting, welding, and grinding. My suggestion is to build one from cardboard first, so you can change things if needed.

It's not hard to make your own bends in plate, but you'll need a welder to finish. I've made several jeep bumpers before I became a 4runner fan. You'll have to mark your line and use a grinder to cut a slot in the metal, but not all the through. Once you cut through about half way (or more), you can use some adjustable wrenches to bend it. After you bend it you'll have to weld the slots up, and grind them smooth.

If you're looking into getting a welder, stay away from Harbor Freight for this one. Their welders are good for thin sheet work, but I wouldn't use them on anything else. My choice would be finding a used or new Hobart Handler 140 and get it up for gas. The 140 should be plenty for what you'll need it for. I have a used Lincoln 140 welder that works good, but I'd take a Hobart over this anytime. Miller welders of course are the best, and you'll pay for it. Look for a used one on Craiglist, and make sure you try it before you buy it. The technique to welding is not hard to pick up. The hard thing about welding is learning how to set you welder, and the speed at which you weld. These things will all come with practice.

My goal is to basically do what you are doing. I also want to make sliders and I am in the process of designing that as well. But with the rear bumper the best scenario would be to have a tire carrier as well. I don't want to steal your design on that but I would love if you could lead me in a way that I can also make that possible.

 

[snivilous]

I built all my gear. I have all the tools so besides time the only cost is metal. I also like to build all my own stuff and apply what I'm learning in college; essentially the exact same as you And besides the sliders, I didn't get too in depth on drawing stuff up, just used cardboard and drawing all the measurements on a napkin and just going at it. The rear was the hardest since it was my first time and there are the compound angles, so I just cut out pieces of cardboard till it looked right and then cut those pieces out.

Sliders are easy as butter to make. I didn't get too fancy with mine, they have a couple degree tilt in on the first foot or so and vice versa on the rear (like a subtle kick in/out) and I put them out far enough to be used as a step which is really nice actually. They're designed and analyzed to be a simple bolt in and then we added some welds for the hell of it. (Ignore the metric FEA, I couldn't get it to convert to English and we did long hand to back it up)

 

[dtc81]

I would stay away from the Home Depot steel. I don't know of the selection or quality of it in your area, but the steel selection at chain stores near me is dismal at best. Search for a steel or fabrication business and they will be able to give you lengths of material, and most likely much better quality stuff at a better price. Always check for "drops" at these places, which is the unwanted portions of steel from various random jobs. These are usually for sale at a heavy discount. Whenever I run into 1/4 or 3/16 plate drops I buy them.

I went with 1.5" .120 wall DOM tube for my bumper build. I don't think I necessarily NEEDED DOM, but I figured do it once, do it right. HREW would have sufficed.

Do you plan to incorporate a hitch receiver into the design as well?

I think some guys that have a little more fabrication experience can answer some questions better than I can. They'll chime in soon.

 

[MStudt]

My goal is to basically do what you are doing. I also want to make sliders and I am in the process of designing that as well. But with the rear bumper the best scenario would be to have a tire carrier as well. I don't want to steal your design on that but I would love if you could lead me in a way that I can also make that possible.

I've got a couple designs on my build thread for sliders, and I think one for a bumper idea I had. Of course these are tube ideas rather than plate designs.

The design is really up to you. My wife and I have different opinions on how things should be made. She'd like to keep the stock bumper, and some how wrap it with tube. I on the other hand would like to design a plate bumper that would closely follow the contours of a stock bumper. I'm still getting my JP Magazines since I just recently converted. There was a nice article in there and showed how someone built a bumper behind the factory one, and it had a tire carrier. The only difference is that the Jeep bumper is frame mounted and the stock 4runner bumper is body mounted. One of the easiest ways to build a rear (IMO) is to use you factory trailer hitch. The way that it is mounted makes it hang down pretty low. You can actually move it up, or cut the mounts off and weld it between the frame rails. A lot of people have done this, and built off of it that way. If you do that, you'll gain a strong recovery point in the rear for free.

Design it with cardboard first, cut and trim as needed, and find what looks good to you. Once you have your mock bumper you're set.

 

[5vzT4R]

Obviously start with the right tools, speed square, tape measure, grinder with cut off disc, grinding disc, a tiger disc (sanding disc) a chop saw or band saw, 6" magnetic level, pipe bender, drill press, writing chalk and the best of all a welder.

Now since your starting out, get a wire feed welder. Either MIG or Flux Core will do just fine.

A quick pro's and con's of each:

MIG welding is way cleaner and IMO easier, but its also requires more metal prep clean up, is more expensive, cant really weld outside very good if there is any wind, and has a big ass bulky gas bottle.

Flux Core welding is pretty much the opposite, it can weld out outside with no problem, requires less metal prep (even though the more prep, the better the weld with any process) doesn't need a gas bottle and is less expensive.

Which ever you go with, no one can ever get to much practice in welding, to much practice doesn't exist. So go buy a welding machine that your wallet can handle. Any Hobart, Miller (basically the same thing) or Lincoln wire feed welding machine MIG or Flux Core will be able to do the job better then you can.

Now that I got the "tools" out of the way, on to the learning how to weld part.

Practice, practice so more and keep on practicing. Look up Chucke2009 on youtube, he has really good advice and doesn't bore you while your watching. Also look at weldingtipsandtricks.com, a very good website to read on welding.

Find a way to try and "test" your weld strength at home, either some type of press machine or big hammer. You don't want your bumper to fall apart on the highway, so please make sure your welds are ready enough. And since your a beginner, don't just butt to pieces together that are anything over 3/16" thick and expect pull penetration, because more then likely it just wont happen. Learn to bevel your two pieces or set a small gap to fill in, or both if your good enough.

Any questions feel free to ask me, no I am not a professional welder (really don't think anyone is in every single process, simply because there is a endless amount of learning and practicing to do) but I have a very good amount of experience in welding (SMAW, TIG, MIG and now Im learning FCAW) and fabricating, as well as others on this site.

Good luck! :bigok: