My Bumper Build

[97 _SR5]

Bumper is making some progress... don't have too much free time so progress is much slower than initially anticipated. But here are some progress pictures and I will update as I get more of it done. Used 3/16" aluminum partially because that's what I had available at the moment. There was definitely a learning curve to working with aluminum, but I think it was a good experience.

Initial design and welding pieces together (don't mind the booger welds... was trying to stick weld it and later ended up switching to a spool gun set up).



a little more welding done and starting cutting out the front for shackle mounts:



ground most of it down and fabricated and welded recessed areas for lights:



test fitting and progress so far:



Thanks for looking,
Rafal

 

[Bry838]

I like the aluminum idea. Kinda wish that was a more common option with a few of the manufacturers. Yeah there is a strength loss, lil bit, but the weight savings is so nice. Where id really like to see an aluminum option is with rear bumpers, especially with swingouts and all the other crap that a guy ends up mounting on there. They get to be crazy heavy when all steel. Too much weight hanging off the back.

 

[97 _SR5]

I like the aluminum idea. Kinda wish that was a more common option with a few of the manufacturers. Yeah there is a strength loss, lil bit, but the weight savings is so nice. Where id really like to see an aluminum option is with rear bumpers, especially with swingouts and all the other crap that a guy ends up mounting on there. They get to be crazy heavy when all steel. Too much weight hanging off the back.

Aluminum rear bumper would be cool... Only problem I see is that everything would have to be fabricated from scratch... Swing out hindge and all latches if you want to weld it on... I'm not sure if anyone makes that to just purchase and weld on...

I'll weigh mine when it's all done but to be honest I didn't use aluminum for weight savings in the front. I read before that the Tacoma aluminum front bumper weighs 70 lbs which isn't that much lighter than some steel bumpers.


I'm assuming most manufacturers don't offer aluminum because quality aluminum that can stand being beat on is expensive... Would probably double the cost of the bumper and manufacturers have to balance good quality with a decent price.

Rafal

 

[Bry838]

Aluminum rear bumper would be cool... Only problem I see is that everything would have to be fabricated from scratch... Swing out hindge and all latches if you want to weld it on... I'm not sure if anyone makes that to just purchase and weld on...

I'll weigh mine when it's all done but to be honest I didn't use aluminum for weight savings in the front. I read before that the Tacoma aluminum front bumper weighs 70 lbs which isn't that much lighter than some steel bumpers.


I'm assuming most manufacturers don't offer aluminum because quality aluminum that can stand being beat on is expensive... Would probably double the cost of the bumper and manufacturers have to balance good quality with a decent price.

Rafal

Who makes the aluminum front bumper?

 

[97 _SR5]

Who makes the aluminum front bumper?

This is the only one I know of... There might be more.

Toyota Tacoma Winch Bumper 01-04 | Aluminess Products, Inc.

 

[Bry838]

This is the only one I know of... There might be more.

Toyota Tacoma Winch Bumper 01-04 | Aluminess Products, Inc.

Damn i had no idea!! Only fur 01's and up though hu? The older frames cant be that different to warrant only listing tham as 01/04's only it would seem. I know like arb for example uses the same.bumper for all, runners included. There are a couple little different pieces with the bumper i remeber when i mounted my arb on my tacoma. Seems like that aluminum one could utilize the same idea...

 

[97 _SR5]

Making progress... Bumper is almost done, just need to put another coat of bedliner on and ready for assembly...

 

[97 _SR5]

So I realized that I never made a mounting point for my license plate. Since the fairlead will be in prime plate location, found a few options online... I want to get the bumper mounted tomorrow so my only option was to make one... It will cover the fairlead but 2 bolts can be easily removed when winch will be needed

 

[97 _SR5]

6 Months later and were're done! Here's how it's' mounted... Front of the bumper has 2 plates (they have welded gussets to the bumper) that sandwich the frame:



I made these mounts for the sides. They mount to OEM bumper bracket location and then to plates on the inside of the bumper:




Ok, finished and mounted:







Thanks for looking, next up is tube flares!

Rafal

 

[kolelt]

That looks badass man. Always loved the look of bumpers that hide the winch. What kinda Bedliner did you use !!

Aluminum is $$$)

 

[97 _SR5]

That looks badass man. Always loved the look of bumpers that hide the winch. What kinda Bedliner did you use !!

Aluminum is $$$)

Rolled it with Herculiner. Once I get the winch rebuilt, I'm probably going to have cut the bumper for clearance... It won't fit completely in there right now with correct angle for the fairlead.

Rafal

 

[cmtul]

I'm liking the work so far man. How much of a curve was it when it came to learning to weld the aluminum?

 

[IBallEngineer]

That looks badass man. Always loved the look of bumpers that hide the winch. What kinda Bedliner did you use !!

Aluminum is $$$)

How do you get to the lever to free wheel the spool?

 

[Clayton74]

A bit off topic but are those 15" wheels and if so did you have to do anything to fit them?

6 Months later and were're done! Here's how it's' mounted... Front of the bumper has 2 plates (they have welded gussets to the bumper) that sandwich the frame:

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Thanks for looking, next up is tube flares!

Rafal