Hybrid Plate/Tube Front Bumper - MojaveMadMan Edition

[T4Rscott]

I got a big/little update. I got my frame mounts all finished up. While it's a small thing, it was a big pain in the ass for me... Took a while to find the frame boss material, and I had to have it shipped to me. Plus drilling all the holes is always fun. Ended up turning out real good though.

A note, this is just the spot where the uprights bolt to the frame, It will also bolt on to the side support factory brackets, the place where the factory tow hooks were, and down low because the skid plate will go down the the frame cross member where the front diff is.

This is the inside of the mount. I added some 1/8" plate to the frame to strengthen it up a little bit. The D-Ring plates will be bolted on to the inside of each frame rail so I wanted this spot to be a little stronger. I also added a plate on the top of the frame because there was a factory hole there. Then after I welded the bosses into the frame inside and out, I capped the frame off with some more 1/8" plate. One small note, I was trying to use 3/4" boss material for the bolt holes but couldn't find any in a length shorter than 6'... so I ended up ordering this 1" x 1/4" wall DOM from Poly Performace. It was $30 with shipping which is way too expensive for a 1' length of tubing, but it was the cheapest way I could get it... I have only lived in Albuquerque for 4 months so I don't know all the spots yet...



This is the outside of the frame rails. No fancy gussets or anything.



Also, I made my D-Ring plates. I don't have a picture right now, but they are 1/2" plate cut and drilled to fit. Once I get the bumper back on and build the uprights I will post more pictures, hopefully this weekend.

I also ordered up a 1.5" die for doing the tube work. I still need to get the bender itself, but got a great deal on the die so I couldn't pass it up. Anyone selling a pro-tools bender? haha

I have a pro-tools bender I will sell.

 

[MojaveMadMan]

Got one now, thanks though.

 

[MojaveMadMan]

Some teasers!!

 

[2014 Warthog]

That bender looks like it's doing it's job. How much floor space does that take up in the garage? A tube bender and a break press are like two things I'm conspicuously missing from my garage...

 

[MojaveMadMan]

That bender looks like it's doing it's job. How much floor space does that take up in the garage? A tube bender and a break press are like two things I'm conspicuously missing from my garage...

Pro-tools does a great job! If your doing manual you need about a 6' half circle around the bender. If you go hydro it's a lot tighter. Of course it depends on how long the tube is too...

 

[MojaveMadMan]

Ok guys and gals, big update. Phase one is complete! I had a good amount of garage time this weekend while the in-laws were in town, so I got what I call phase one complete. I have completed the main bumper minus a couple small things. I tried to track town 3/8" trick tabs in ABQ, but nobody sells them out here so I pressed on. So I still need to add the trick tabs for the skid plate to bolt on to the bumper. I also need to get the skid plate cut, still doing 1/4" aluminum, and I am having a large vent area cut out where I will install some cool mesh material.

Phase two will consist of building a small sub frame that goes from the bumper to the cross member on the rear pivot of the LCA. This will then hold another 1/4" aluminum skip plate to protect the diff, steering rack, etc. I need to order up some couplers, tabs, and I need more tubing to do this so that's why I am calling it phase two. It probably won't happen for another month or so...

Other notes, so my blinkers look great, but they aren't as bright as I was hoping they would be. The LED's aren't that bad, it's mainly because of the downward angle, it makes them hard to see in the day time. I will come up with something to fix this, just not sure yet. I know I am legal now, so it's honestly a low priority. Lots of pictures, enjoy them! I will add the small updates as I get around to doing them!

Last thing to note, I ended up having to cut out my grill so the center light could fit. I still need to buy a center light as well. I wasn't planning on doing a satoshi grill, but it was a good trick to have in the tool box, so I didn't hesitate to cut the grill out. So I will be doing that on the main build thread at some point. I was actually ok with this because the idea for the bumper was not to have it stick out too much. So cutting into the grill to stuff big lights in is right on par with this idea, overall I am pleased.

Last of the build pics:
















Finished (for the moment) Pics, I even busted out my good camera for these!

























The drivers view, doesn't block much at all!

 

[txbonds]

That turned out awesome. Great job. I like it. :cheers:

 

[MojaveMadMan]

A funny pic I took yesterday while cleaning my disaster of a garage, so much grinding dust everywhere... should have taken before and after shots.

[http://s1255.photobucket.com/user/d...-4580-8658-05942EE0B38C_zps0a6y7gfw.jpg.html]

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[MojaveMadMan]

So almost a year later I finally got this thing finished. I removed the bumper blinkers and put them where most people do with yellow optical LEDs. I cut my skid plate from 1/8 aluminum and dimple died it. These are 1" dimples, I think 1.5" might have been better. I will see how hot it gets this summer and might make a new one with larger holes if needed. I also added tabs for a front diff skid I am working on. Should be done in the next week and I'll add pictures when it's finished. Lastly I re-painted it a satin black to test out a new color. I have decided to Line-X my limited flares so I think I am going to eventually powder coat the bumper a wrinkle black in the future. I also want to add a winch mount, but that's a whole different adventure...

 

[JBurt]

Well let me be the first to say congratulations. Looks fantastic!

 

[RockenAlex]

[MENTION=84643]JBurt[/MENTION] beat me to it but dang man! Better late than never.

This very well could be the coolest bumper I've ever seen on a 3rd gen. If I go didn't already have a bumper this is exactly what I would be aiming for! You're attention to detail is unbelievable. I'd have liked to see how those in bumper turn signals came out but can't say as I blame you for ditching them.

Again I applaud the effort and will be saving this thread for the future just in case! Oh and I want to see how the winch thing works out for you. :thumb:

 

[kolelt]

I really like it. I like how it's small yet beefy. Its low profile and looks clean. Good job man. Really !! Well done.

 

[Kryptoroxx]

it looks fantastic!! I like the simple lines as well. You can definitely see the baja influence but it's beefier. I bet it's fairly light as well.

Nice welds too lol. Much better than mine. I'm getting better though.

 

[MojaveMadMan]

Thank you everyone for the good words!!! I have nearly 100 hrs into this thing.. probably would have been cheaper to buy one, but I like having my own haha.

 

[MojaveMadMan]

My bumpers are up for sale. If anyone wants them please let m know!

Thread here: http://www.toyota-4runner.org/sale-...r-plate-bumpers-w-accesories.html#post1982599