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Demello 4th Gen rear bumper - closed

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[MENTION=59079]jdemello[/MENTION]

We're at 22 interested members right now. How serious are you about designing something for the 4th gen rear? There are a few offers from members to use their 4th gens as templates.
 
Curious to see what yours looks like completed with the dual swing out. Haven't found any pictures online, which has kept me from purchasing.

Not to clutter the thread but...4x4Labs dual swingout here. Mine may look a bit different on the sides since I have a body lift too and tried to keep a bit of plastic, but you can get an idea of what it may look like. Excited to see [MENTION=130999]Inv4drZm[/MENTION] 's as well when he's done.

http://www.toyota-4runner.org/4th-gen-t4rs/190858-justinbs-06-build-thread-3.html#post2933244 (link is direct to post of pictures of my rear bumper)
 
Subscribing out if interest. I had contacted Jason a while back about a rear bumper. It seems like they could do it but would need my truck there. Living in AL that wasn’t possible. I would suspect if they were going to start producing rear bumpers it would start with the 5th gens since there would be more interest there. Believe me, i would love to have a Demello rear bumper to match my front bumper and sliders but had to go with CBI dual swingouts since i do not have the sources or skills to fab a 4x4 Labs bumper.
 
Thank you everyone for the interest. Thank you William for starting this post.

The biggest issue with us releasing a new product like this is interest obviously. We need lots of it and it needs to be fairly consistent to justify producing this.

That said, this thread shows there is some interest in a bumper like this. We have built a couple in the past for customers on a custom basis.

There are a few hurdles to overcome with a rear 4runner bumper of any kind. First and foremost is cost, they are expensive to produce and expensive to ship. We have found in the past to make things modular always works better for the customer and for us. In other words you can order a plane jane bumper bare-metal or you can order a fully swing out powder coated beast ready to go. Even at this it wouldn't be a cheap option. And on a vehicle that's already 20 years old plus, we find it a hard sell to some.

The other part of the equation is managing expectations. Rear bumpers are heavy, there is a lot of steel and a lot of weight associated with that back there. Aluminum isn't even an option for most unless everyone wants to spend in excess of 5k for a for a swing out. Steel you are looking at a 150-200lb bumper before you add a 100lb tires on there and 25-30 lbs of gas can and what ever else you want.

Understanding that once you put a rear bumper on like this, if you often use your rear door it will become more of a chore to open it in a parking lot with one or two swing outs in the way.

These are just some of the things one needs to think about.

Our own shop 4runner has never had a swing out. I have recently decide I will be building a rear bumper for our 4runner but not sure if I will add a gate. I personally don't like all that weight back there but I'm also running out of space with a 3rd row and 4 kids!

Now to answer some of the questions below.


1) Weight....this is a big one for me, as I already have a lot of added weight with my overland build.

This is always a concern, I would recommend a set of stiffer rear coils like the OME heavies or Icon over land rear springs with any rear swing out.

At minim a rear bumper is 100lbs of steal. A swing out adds roughly another 75-100lbs. These weights are nothing compared to the compounded weight of a spare tire and wheel roughly 100-150lbs for those running heavy tires. I know my 35's on light 17in aluminum wheels weigh around 140lbs. And it hands out over the rear creating leverage on the rear of the 4runner. combine this with a couple gas cans full of gas and you are tipping the scales. Just something to think about before you add this to your wish list.

2) swing-out options (preferably dual) for a rear tire carrier, jerry cans...etc

That's been the way I've been leaning for a swing out, there simply isn't enough frame support to do a one arm option if you want it to hold together and last.

3) smooth, sleek, yet rugged design that compliments the 4runner. I also am not a huge fan of the CBI rear, as it looks very bulky and doesn't seem to compliment the lines of the 4runner as well as it could. I like coastaloffroad's design although I would prefer it come up the sides (instead of having to cut part of the rear panel).

Unfortunately it will be a cut version. Main reason is weight but look at anyones rear bumper that didn't cut after they have taken it off road and you will see clear places where it rubs the body, unless it has an inch gap. Toyota's body on frames flex and they flex a lot. having a bumper run up to the metal part of the body is almost a guarantee you will have a couple worn spots.

We currently have all our newer front bumpers require cutting for this reason and we are working on fiberglass replacement pieces on our new 4runner bumpers for those that hate cutting.


4) departure angle.....as good as it can be. This is very important to me, as I feel my departure angle is a limiting factor for my offroad route selection.

This is difficult as well. some require you to cut your rear frame which is scary for most. I'd prefer this but most likely we will build it so you "DON'T" have to cut your frame.

5) relatively simple install with lots of strong mounting points.....it has to be tough, safe, and strong. Personally I'm not at all opposed to chopping the rear cross-member and doing some grinding work (such as 4x4labs kit), if it saves a fair chunk of weight and increases the departure angle, so long as the rear bumper replaces that cross-member's function and adds the strength back.

I'm not sure I would feel comfortable with a bolt on piece to replace a welded in piece but we could look at it.

6) ship welded together and ready to install......there are lots of weld-together bumper kits on the market, some really good ones in fact, but the cost for me to have someone weld it together, brings it close to a CBI rear, and is a lot more time-consuming and inconvenient for me.

Yes, which is part of the reason why we really don't want to go that route, the problem becomes people want the bumper super cheap but want everything in it. We get it, we do too, but this is honestly a large part of the reason we don't make one and very few others do.

8) price point....I know rear bumpers are costly to R and D, and build, but I know that if the price point were lower than your competition, it would attract more customers to you. I think the pricing on your sliders and bumpers are good, especially with the discounts you guys frequently offer.

This is one of the major reasons why we haven't come out with one yet. There isn't much of a price increase or margin on something like this. They are very costly and time consuming to design, build and store. We may even keep it a simi custom option where people can order it to fit their needs. We also don't like to build something like this unless it's right with the right parts and the right design. that all adds up. Our rear swing out for the FJ isn't cheap and honestly we need to increase it's cost because it's a low money maker for us and is extremely time consuming to build and the support we have to supply with it, we'd have some happy people here if we deleted it off our menu.


That all said, we aren't against building one and having a rear 4runner bumper in our line up. I think we need to know who wants just a rear bumper and who wants a swing out? also price point where is everyone at realistically in terms of what you would want to spend on a rear bumper and rear bumper with swing out. If everyone wants a 1000 rear bumper but our material cost alone are right there then it makes no sense to go any further for us. But if people want to see a different option and value is determined by what they get for that money then we may pursue a rear bumper design.
 
Thank you everyone for the interest. Thank you William for starting this post.

Thank you for the well thought-out and thorough response.

I don't speak for everyone, but personally, I would not be opposed to a "kit" style bumper that requires some welding on the part of the end user to save some of your costs. One of my big reservations with the Coastal Offroad bumper is it looks pretty prone to warping during the welding process since it's 100% flat plate, with no formed pieces to provide some rigidity. If your design could take that into account, I think you'd have a moderately successful product. I realize every weldment will warp in some capacity, but as I'm sure you're aware some designs are better at mitigating that than others. Basically, if your bumper could be successfully welded together without needing a Bluco table, that would be awesome.

When the time comes to start taking down names and for "official" updates or deposits, please let me know. Personally, I would like a rear swing out since I need a good way to carry a 33" spare.
 
Thank you for the well thought-out and thorough response.

I don't speak for everyone, but personally, I would not be opposed to a "kit" style bumper that requires some welding on the part of the end user to save some of your costs. One of my big reservations with the Coastal Offroad bumper is it looks pretty prone to warping during the welding process since it's 100% flat plate, with no formed pieces to provide some rigidity. If your design could take that into account, I think you'd have a moderately successful product. I realize every weldment will warp in some capacity, but as I'm sure you're aware some designs are better at mitigating that than others. Basically, if your bumper could be successfully welded together without needing a Bluco table, that would be awesome.

When the time comes to start taking down names and for "official" updates or deposits, please let me know. Personally, I would like a rear swing out since I need a good way to carry a 33" spare.

I wouldn't be afraid of welding together flat plates to form a skin, in fact that's what I did for most of my front bumper and I designed it that way so I could fine-tune the fit exactly how I wanted which is important for a prototype one-off. Bend parts with multiple angles are a bit trickier in my experience to line up with eachother (My 4x4labs rear bumper I'm looking at you!) although they do offer more strength and less welding and grinding time and potential for heat warping, but the person welding can do quite a few things to minimize that including tack welds and shorter passes to allow cooling.

I would prefer the strength and reduced welding/grinding time of a bend part as long as it is well designed to line up easily with the plate next to it. Otherwise it wouldn't be a deal-breaker for me if they simply used flat plates as long as I liked the design overall.
 
Id like to see one, see how its built before I say either way. Im hoping its stronger than the front I had on my 04. :dancin:
 
[MENTION=59079]jdemello[/MENTION] you raise some good points. As far as what one is willing to pay, Pelfreybilt is charging $3200 for their new 5th gen rear bumper with dual swing out and I'd be willing to pay that for a 4th gen. Make it aluminum and I'd be willing to pay $4200.

http://www.toyota-4runner.org/5th-g...dual-swing-out-rear-bumper-pre-order-now.html

3200.00 honestly would be a good starting price. There are a lot of reasons why they cost so much. Aluminum... I shutter at the cost, things like bearing spindles need to be machined out of thicker material. Honestly I don't see those being strong enough with out tigging them to the arm (even more money). The latches would have to be aluminum as well too with steal parts. Then the tire mount would have to bolt on and be steal because of the studs, I doubt anyone wants aluminum wheel studs:) I would love aluminum too but the cost difference would be crazy.
 
Thank you for that detailed response!

I am in the market for a dual swing out and would expect a quality bumper with all the fixings to start around $3,000.
 
3200.00 honestly would be a good starting price. There are a lot of reasons why they cost so much. Aluminum... I shutter at the cost, things like bearing spindles need to be machined out of thicker material. Honestly I don't see those being strong enough with out tigging them to the arm (even more money). The latches would have to be aluminum as well too with steal parts. Then the tire mount would have to bolt on and be steal because of the studs, I doubt anyone wants aluminum wheel studs:) I would love aluminum too but the cost difference would be crazy.

Obviously, I've never built a bumper. That's why I'm a microprocessor engineer and not a fabricator. Thank you for the education. :)
 
[MENTION=59079]jdemello[/MENTION] you raise some good points. As far as what one is willing to pay, Pelfreybilt is charging $3200 for their new 5th gen rear bumper with dual swing out and I'd be willing to pay that for a 4th gen. Make it aluminum and I'd be willing to pay $4200.



http://www.toyota-4runner.org/5th-g...dual-swing-out-rear-bumper-pre-order-now.html



Same here, $3200 doesn't strike me as unreasonable for a good fully welded bumper with dual swing outs.
 
3200.00 honestly would be a good starting price. There are a lot of reasons why they cost so much. Aluminum... I shutter at the cost, things like bearing spindles need to be machined out of thicker material. Honestly I don't see those being strong enough with out tigging them to the arm (even more money). The latches would have to be aluminum as well too with steal parts. Then the tire mount would have to bolt on and be steal because of the studs, I doubt anyone wants aluminum wheel studs:) I would love aluminum too but the cost difference would be crazy.

You could offer an aluminum plain-jane bumper, no swing-out, to satisfy the 'lightweight or bust' crowd. Not sure if it is safe to put an aluminum tow hitch receiver tube on there or if there would be a large enough performance gain over the stock bumper all things considered but it might be an option.

I agree with trimming and using part of the stock bumper, it would set yours apart from the other bumpers out there.
 
You could offer an aluminum plain-jane bumper, no swing-out, to satisfy the 'lightweight or bust' crowd. Not sure if it is safe to put an aluminum tow hitch receiver tube on there or if there would be a large enough performance gain over the stock bumper all things considered but it might be an option.

I agree with trimming and using part of the stock bumper, it would set yours apart from the other bumpers out there.

That's actually what I want.

I have even spent considerable amount of time under our 2016 trying to figure out how to make a kit to mount a 35in tall tire. I think a 33 or 285 would be easy but 35in is very difficult.

I believe heavy stuff like that should be down low as possible. I currently throw my tire on the roof rack and have a spinner mount to hold it down. It works great till I get off camber and remember I have 140lbs of tire up there wanting to pull me over.
 
Thanks so much for that very detailed reply Jason.

You're welcome for starting this thread. I hope it's shown that there's a lot of interest in a rear swing-out from you guys, and we haven't even touched the facebook enthusiast groups, or other social media forums.

I think everything you've said makes sense, and although there will never be a consensus from everyone on design details, such as "requires cutting vs not," I think there are a lot of common sentiments by the members.

You've listed a lot of cons to purchasing a rear bumper, which is nice, because they are definitely considerations for buyers, but I think most of us that are at this stage in our build, know what we're in for, and know what we need for suspension upgrades, to handle that weight. Personally I'm looking at either metaltech Heavy LT springs, Dobinsons, or ARB's extra heavy springs, but leaning towards the metaltech's dual rate with L and R specific springs....anyways I digress.

I know a lot of people have suggested a price point around the 3200 dollar mark is reasonable. Personally I would like to see a product around the CBI or other built 4th gen rears mark, or slightly lower if possible. I believe those ones are around 2500 for a built swing-out rear.

It would be nice to maybe see a sketch of what you are imagining? You mentioned you have built some custom ones in the past? I haven't been able to find any on google or forum searches. Were there any you were very happy with, that you could show us pictures of? Do you guys have a shop 4th gen that you can model on, or are you in need of a eager volunteer to build one off of?

Thanks Jason!

Will
 
I already have a rear bumper with swing out so I don't have a dog in this fight, but I would have totally bought a Demello rear bumper if it was an option. Mostly because they're local in So Cal and I do like to save money on shipping plus support the local guys, but also because I've got a Demello front and I absolutely love it. I have no doubt a Demello rear would be absolutely sexy.

That being said. A good price point is between 2k-3.5k At one point a rear CBI with swingout, table, and powder coated was only around 2k. They raised their prices a few years ago and that seriously put me off (2700 with swing out, cans, and table) Most of the cut your own bumper trim options come in around 1500-2k. RPMFAB with dual swing out, jerry cans, and powdercoat comes in around 2400 (no bumper cutting required). And then as mentioned you have your weld your own that come in around 1k.

Cutting your bumper vs bolt on. Cutting was a turn off for me. If I hadn't completely destroyed my rear bumper on some rocks it would have been nice to recoup a couple hundred selling it. Yes it adds on more weight, but personally it just looks tacky. I can't imagine it's more than an extra 5-10 lbs of steel and is that really going to make a difference?

Rear coils are an absolute must. I was running 2" Metal Tech medium coils pre bumper and had to upgrade to 3" MT Heavy coils to handle the weight. I still lost about 1/2" - 1" of height once the coils were broken in. My custom rear bumper comes in around 200 lbs + 35" tire/wheel (another 85ish)
 
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