Hybrid Plate/Tube Front Bumper - MojaveMadMan Edition

[MojaveMadMan]

A little pre-face. I have been planning this bumper for a few years now. I originally wanted to build this for my Tacoma, but even better, it's going on my 3rd Gen! I have seen a few "hybrid" bumpers before, but nothing like this. I come from a desert racing back ground, but now days I am more into expo type trips. I really want to make something that encompasses both styles.

So here is the plan, I want to build a pre-runner style bumper that has elements of and expo style plate bumper. So the idea is the put a plate bumper in place of the main tube most pre- runner bumpers have, then use tube work on top and on bottom for the skid plate.

The plate part is 1/8" mild steel. I want to save some weight on this thing, while still keeping it stronge. Then the tube work will either be 1 1/2" or 1 3/4", I haven't decided yet. The skid plate will be made from 3/16" aluminum plate that I think will be very stronge once paired with the tubing.

Other details will come as I build. This will be a slower build, I only get a couple hours a week to work on this thing (wife and kid keep me busy), plus I am still trying to track down access to a tube bender, or I need to pony up and buy one. I had to sell mine a year ago to fix my DD at the time, so I am itching to buy one again. A short back ground, I built off-road race and high end play cars/trucks for over 10 years before joining the Air Force, so I do have a good amount of experience to draw from, but I'm still learning every day!

 

[MojaveMadMan]

This is my first couple days of work. I have the main shape of the plate part built. I still have a long way to go just on the plate, then into tubing... Enjoy!!!

 

[CdaleR4000si]

I like it already. Looks like it is streamlined. I can't wait to see how it progresses!

 

[morbidsanity]

badass man....im going back to welding school, one of my projects was to make an addicted offroade style tube bumper.....after this its going in a plate/tube bumper!

 

[kolelt]

That kooks great bro. I like how it's not so beefy looking but strong looking. Nice bed liner paint would make it bad Ass , such as raptor Berliner.

 

[Dee3]

Good looking bumper.. Nice approach angles, looks sleek, interested to see how it turns out.

 

[Skidmarcx]

You got my attention! Looks like a great start!

 

[MojaveMadMan]

Thanks for the compliments everyone! I'm glad you guys like my vision. I will share more pics once I get home (on the road for work right now). I took a different approach on a few things like how u cut the front of the frame, and how I will be doing the blinkers (next on the list). Oh ya, and I got a cool idea for D-ring mounts too, haha. I'll keep the pictures coming. Thanks again for all the good words!

 

[Dezert4Runner]

That bumper looks great man. I had a nearly identical bumper design in my head to build (in the not so near future) after I finish my welding class and pick up a mig welder. Are you going to box the uprights? Are you using any tube for side support going from the mounting bracket to the corners? I'll be following this closely!

op2:

 

[MojaveMadMan]

That bumper looks great man. I had a nearly identical bumper design in my head to build (in the not so near future) after I finish my welding class and pick up a mig welder. Are you going to box the uprights? Are you using any tube for side support going from the mounting bracket to the corners? I'll be following this closely!

op2:

Full boxed uprights, with integrated 1/2" plate D-Ring mounts directly to the frame. I am also boxing in the end of the frame and welding in some 3/4" tubing where the bolts go threw for added strength. The uprights will also wrap under the frame a bit to get a couple more bolts. 1" tube side supports as well.

That kooks great bro. I like how it's not so beefy looking but strong looking. Nice bed liner paint would make it bad Ass , such as raptor Berliner.

Was thinking about the bed liner. I want to also remove all the limited body cladding, weld in the holes, and bedline the sides of my 4runner. I would pay a shop like Line-X though, I would want a pro job!

 

[Bandit Runner]

Very interesting design. Can't wait to see more of it.

 

[white_n_slow]

subscribed

 

[Hepar]

Looks good! My only suggestion is to maybe increase the gap between the bumper and the grille. If you plan on using it, it will flex a bit and you'll want a bit of space there.

 

[krenaud33]

Looks good! I can't see the mounting very well, but it doesn't look like it would take much impact. Are you still working on that aspect?

 

[MojaveMadMan]

Looks good! My only suggestion is to maybe increase the gap between the bumper and the grille. If you plan on using it, it will flex a bit and you'll want a bit of space there.

Thanks for the suggestion. It will get adjusted down once I weld the 3/4" tubing into the frame. I've actually been having a little trouble sourcing a small amout of the 3/4" I need locally... Once I get it, the bumper will get it's final spacing adjustment. Thanks for looking out though, this will get used for sure!!!

 

[MojaveMadMan]

Looks good! I can't see the mounting very well, but it doesn't look like it would take much impact. Are you still working on that aspect?

In the very early stages with the mounting. All I have right now is the bare minimum so I could built the shell of the bumper. Going into that area next. It should be very tuff. Didn't post pictures of the mounts because there isn't much to show yet. I'll post detailed pictures once it's in work.

 

[MojaveMadMan]

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

 

[MojaveMadMan]

Got some more work done yesterday. Got my uprights almost finished, and D-Ring plates on. Now I just need to finish up the rest of the plate part of the bumper before moving on to tubing. I have to do the plate work on the bottom, cap the ends, and run the outward support tubes. I should be able to get all that done next weekend. then it's time to weld and sand...

Here is an overall picture.


This is a shot of the upright from the outside of the pass side.


And the inside of the drivers side, you can see the D-ring mount and how I used it a a bumper mount, and part of the upright.


One from the side for fun.


And one more view, this one I put into my CAD program to lay out the tube work for you. I normally don't do plans, I just do it all in my head, one part at a time. But it's hard to describe, so here is a quick render so you can see where I am going with this one.

Green is HID lights, Red is 1.5" tubing, and Blue is plate. The lights will be the "Kragen" style HID lights with internal ballasts. The tubing will be 1.5" mild steel 0.120 wall tubing that will wrap all the way under the oil pan and diff, and will end at the cross member. The plate will be more 1/8" steel plate on either sides of the skid plate. Then the plate for skid plate I have decided on some 1/4" aluminum, and I will cut some sort of vent out of the center for air flow to the radiator and trans cooler. Enjoy!

 

[Elesage]

I love your bumper , and i wich i had your hability, your know how.....
Continu your good work....:cheer2:

 

[MojaveMadMan]

I love your bumper , and i wich i had your hability, your know how.....
Continu your good work....:cheer2:

Thanks for the good words. The right tools go a long way, and then a little practice never hurts, haha.