youwitdaface
New member
As someone learning solidworks, I'm curious as to your methodology for making sure your model will be properly dimensioned to the rest of the truck, if you don't mind
Jake's '99 Limited "Build" Thread
- Thread starter Team_Jake
- Start date
As someone learning solidworks, I'm curious as to your methodology for making sure your model will be properly dimensioned to the rest of the truck, if you don't mind
Team_Jake
Member
[MENTION=280676]HawkPlt[/MENTION] [MENTION=278551]youwitdaface[/MENTION]
I guess I'll throw in a little teaser...
Goals:
I basically incorporated the design of every bumper I liked, there's a little bit of Shrockworks, Addicted Offroad, and Outdoor Logic in there.
The winch mount plates and internal frame is 0.25", the d-shackle mounts are 0.75", and the rest is 10-gauge steel (I might switch to something thicker, not sure yet). Currently it weighs 82.66 lbs, I'd like to keep it under 100 lbs once I add a hoop and mounts that will attach to the wings. Fog lights are made to fit Baja Designs Squadron Sports/Pros. The winch plate is made to fit the Warn M8000. The vertical frame will also be able to mount the winch control box and keep it hidden from view, and an extended control cable will be routed to the top of the bumper through a hole I haven't added yet.
I'm using the frame brackets from Shrockworks because their bumper attachment points are superior to anything else I've seen. I called Shrockworks and ordered a set of the frame brackets with all the hardware, it was ~$130 total.
I made a cardboard mock-up of just the top plate of the bumper, I made 3 different cutouts before I found something that fit the way I wanted.
(I later added another edge, so the wings are 3 edges instead of 2.)
I'm not done with it yet, I still need to add a hoop to the bumper, and I will be adding mounts that will attach to the wings, plus a bunch of little things need buttoning up.
My plan of attack is to completely finish my first prototype in SolidWorks, and then make the bumper by hand out of poster board and test fit. From there I'll make adjustments, and do a 2nd, 3rd, or however many prototypes until I feel i'm ready to have it laser cut and welded together.
...
And just to throw this out there, this is actually my first time ever attempting something like this. I've never had anything laser-cut before, I've never designed car parts before, nothing like that, so if anyone sees anything I am doing wrong please chime in.
I guess I'll throw in a little teaser...
Goals:
- High clearance and high approach angle
- Line up with fender flares
- Light weight
- Clean and low profile
I basically incorporated the design of every bumper I liked, there's a little bit of Shrockworks, Addicted Offroad, and Outdoor Logic in there.
The winch mount plates and internal frame is 0.25", the d-shackle mounts are 0.75", and the rest is 10-gauge steel (I might switch to something thicker, not sure yet). Currently it weighs 82.66 lbs, I'd like to keep it under 100 lbs once I add a hoop and mounts that will attach to the wings. Fog lights are made to fit Baja Designs Squadron Sports/Pros. The winch plate is made to fit the Warn M8000. The vertical frame will also be able to mount the winch control box and keep it hidden from view, and an extended control cable will be routed to the top of the bumper through a hole I haven't added yet.
I'm using the frame brackets from Shrockworks because their bumper attachment points are superior to anything else I've seen. I called Shrockworks and ordered a set of the frame brackets with all the hardware, it was ~$130 total.
I made a cardboard mock-up of just the top plate of the bumper, I made 3 different cutouts before I found something that fit the way I wanted.
(I later added another edge, so the wings are 3 edges instead of 2.)
I'm not done with it yet, I still need to add a hoop to the bumper, and I will be adding mounts that will attach to the wings, plus a bunch of little things need buttoning up.
My plan of attack is to completely finish my first prototype in SolidWorks, and then make the bumper by hand out of poster board and test fit. From there I'll make adjustments, and do a 2nd, 3rd, or however many prototypes until I feel i'm ready to have it laser cut and welded together.
...
And just to throw this out there, this is actually my first time ever attempting something like this. I've never had anything laser-cut before, I've never designed car parts before, nothing like that, so if anyone sees anything I am doing wrong please chime in.
Last edited:
phattyduck
Elite Member
Good choice on just using the Shrockworks brackets. Clean up the frame horns really well or they won't sit flat. You might have to clearance your radiator bracket for the tab that goes back down the frame, depending on what radiator you have:
I just removed the small skid plate crossmember (using shrockworks skids too)- consider tying new skid plates to the front bumper in some way. You'll probably also want to put in the frame end plates with welded nuts for maximum strength.
-Charlie
I just removed the small skid plate crossmember (using shrockworks skids too)- consider tying new skid plates to the front bumper in some way. You'll probably also want to put in the frame end plates with welded nuts for maximum strength.
-Charlie
Team_Jake
Member
Yeah I have the frame end caps with all the hardware, I’ll definitely be using those.
And that’s a great idea to just remove the skid plate cross member and tie it in with the bumper, I hadn’t thought about that before. I had thought about tying in the skid plates in with the bumper but I couldn’t think of a way to do it without needing to remove the skid in order to remove the bumper or without some misalignment, but your idea solves that. Thanks!
youwitdaface
New member
This is awesome. I'll be following this closely - hope it goes well!
Team_Jake
Member
Little update...
Plenty has happened in the last few months (vacationed to Maui in November, vacationed to Jackson Hole over New Years, quit my job last week, starting a new job next week), but unfortunately not much has happened with the 4Runner.
I have though finished everything with the front bumper design. Here is the final design:
Everything will be laser cut here in the next few days. I will create a new thread and write up showing the whole process (final measurements, design tips, prototyping, file formatting & exporting, nesting, welding, powder coating, etc.) once the bumper is finished, so anyone interested can tackle a custom bumper project like this.
Currently my 4Runner is bumper-less since I cut the frame rails to prototype, and installed the Shrockworks frame brackets.
Hope to have this all done before the end of the month. I'll be updating then...
Plenty has happened in the last few months (vacationed to Maui in November, vacationed to Jackson Hole over New Years, quit my job last week, starting a new job next week), but unfortunately not much has happened with the 4Runner.
I have though finished everything with the front bumper design. Here is the final design:
Everything will be laser cut here in the next few days. I will create a new thread and write up showing the whole process (final measurements, design tips, prototyping, file formatting & exporting, nesting, welding, powder coating, etc.) once the bumper is finished, so anyone interested can tackle a custom bumper project like this.
Currently my 4Runner is bumper-less since I cut the frame rails to prototype, and installed the Shrockworks frame brackets.
Hope to have this all done before the end of the month. I'll be updating then...
A couple small updates:
I installed an UltraGauge a few weeks ago, I've been very happy with it.
Did/do you have any issues with trying to figure out the gas tank size? I know the 3rdd gen is a 18.5 gal tank but I would always run dry before the ultragauge showed I was empty, had to put my tank size to 13.2.
Team_Jake
Member
I used to set my tank size in the UltraGauge at 18.5 gallons. A few months ago I was running low on fuel where my UG said I had exactly 2 gallons left, and right when I was pulling into the gas station I felt the engine get starved of fuel. I think when I was pulling into the gas station my fuel was sloshing around in the tank and some air got sucked into the fuel pump, regardless I now know that is my absolute limit. So now I set my gas tank size to 16.5 gallons.
I also set an alarm to go off when I’m at 1 gallon of fuel or less. I try to never get that low, you can kill your fuel pump pretty quickly if it pumps air too often.
Team_Jake
Member
All of the metal has been ordered and should ready to pick up next week.
In the meantime, I upgraded my brakes. I'm now rocking the 13WL Tundra brakes.
Here are the parts I used:
Calipers - AutoZone Duralast C9950 & C9951 (comes with lifetime warranty)
Rotors - Toyota 43512-0C011
Pads - Toyota 04465-35290
Shims - Toyota 04945-0C030
(also just want to throw a little shout-out to Adam at the Toyota Carlsbad Parts Center who price matched everything with Camelback, he saved me ~$100)
No problem fitting the 16x8 VTX Rebel wheels:
In the meantime, I upgraded my brakes. I'm now rocking the 13WL Tundra brakes.
Here are the parts I used:
Calipers - AutoZone Duralast C9950 & C9951 (comes with lifetime warranty)
Rotors - Toyota 43512-0C011
Pads - Toyota 04465-35290
Shims - Toyota 04945-0C030
(also just want to throw a little shout-out to Adam at the Toyota Carlsbad Parts Center who price matched everything with Camelback, he saved me ~$100)
No problem fitting the 16x8 VTX Rebel wheels:
T4topher
Member
All of the metal has been ordered and should ready to pick up next week.
In the meantime, I upgraded my brakes. I'm now rocking the 13WL Tundra brakes.
Here are the parts I used:
Calipers - AutoZone Duralast C9950 & C9951 (comes with lifetime warranty)
Rotors - Toyota 43512-0C011
Pads - Toyota 04465-35290
Shims - Toyota 04945-0C030
(also just want to throw a little shout-out to Adam at the Toyota Carlsbad Parts Center who price matched everything with Camelback, he saved me ~$100)
No problem fitting the 16x8 VTX Rebel wheels:
That’s legit they price matched you! I don’t think they do that very often.. looks good can’t wait to see that bumper!
Team_Jake
Member
I got (almost) all of the pieces back from the metal shop. They called me and said everything was ready to pick up but when I got there, the two 3/4" shackle mounts hadn't been cut yet, so I am still waiting for those.
In the mean time I test fit the 1/4" structural pieces with the winch. Everything fits absolutely perfectly so far. I designed these pieces to slot together so I can test fit everything without needing to tack weld or use jacks or anything like that.
Just enough space for the A/C line:
I still need to get the 3.5" tube cut that will hold the fog lights, and I need to order, bend, and cut the hoop. After that I'll finally get to welding and painting (anyone have recommendations for paint or should I just powder coat?)
...
And for fun I also designed and cut out a few speaker stands with the excess 10 gauge sheet. These will hold some on-wall Sunfire speakers for my brother-in-law's living room.
In the mean time I test fit the 1/4" structural pieces with the winch. Everything fits absolutely perfectly so far. I designed these pieces to slot together so I can test fit everything without needing to tack weld or use jacks or anything like that.
Just enough space for the A/C line:
I still need to get the 3.5" tube cut that will hold the fog lights, and I need to order, bend, and cut the hoop. After that I'll finally get to welding and painting (anyone have recommendations for paint or should I just powder coat?)
...
And for fun I also designed and cut out a few speaker stands with the excess 10 gauge sheet. These will hold some on-wall Sunfire speakers for my brother-in-law's living room.
Team_Jake
Member
Also as quick side note, I got my transmission temperature sensor working on my UltraGauge MX (shoutout to GLR on TacomaWorld for figuring out the last clue). These are the codes if anyone is interested:
TData: 686AF101B40000
TCtl: 85
RCtl: 00
RPos: 2808
Mtch: 41B400
X: 0009
/: 0005
+: FFD8
Out Format: 00
Ave: 00
Left/Right: 31
TData: 686AF101B40000
TCtl: 85
RCtl: 00
RPos: 2808
Mtch: 41B400
X: 0009
/: 0005
+: FFD8
Out Format: 00
Ave: 00
Left/Right: 31
jkeith.w
Official Vendor
Little update...
Plenty has happened in the last few months (vacationed to Maui in November, vacationed to Jackson Hole over New Years, quit my job last week, starting a new job next week), but unfortunately not much has happened with the 4Runner.
I have though finished everything with the front bumper design. Here is the final design:
Everything will be laser cut here in the next few days. I will create a new thread and write up showing the whole process (final measurements, design tips, prototyping, file formatting & exporting, nesting, welding, powder coating, etc.) once the bumper is finished, so anyone interested can tackle a custom bumper project like this.
Currently my 4Runner is bumper-less since I cut the frame rails to prototype, and installed the Shrockworks frame brackets.
Hope to have this all done before the end of the month. I'll be updating then...
oooh! - that looks great!
Team_Jake
Member
Thanks Keith! That’s a big compliment to me coming from you!
Team_Jake
Member
Mounted the bumper for the first time with it (mostly) welded together. It fits perfectly everywhere except just under the driver side turn signal (I never really noticed but the fender on mine is bent in and down just a little. Looking back on old photos I can see I've had this little bend for a long time, probably since before I bought it). Not a problem though, I'll bend it back out.
I've been really busy with work and will be moving at the end of the month so it probably won't get done until mid April or so. In the mean time though, a couple of teaser photos...
(don't mind the gorilla tape)
I've been really busy with work and will be moving at the end of the month so it probably won't get done until mid April or so. In the mean time though, a couple of teaser photos...
(don't mind the gorilla tape)
4runnerfiend
New member
just found your thread. nice rig.. jealous of the manual locking hub conversion!
Bumper looks sweet too. My bother and good friend are in Carlsbad, we go wheeling together all the time. You ever look at the SoCal part of the forum?
Bumper looks sweet too. My bother and good friend are in Carlsbad, we go wheeling together all the time. You ever look at the SoCal part of the forum?
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