My first plate bumper build

[shaunredone]

Ok, first off, this is my first post on any forum, so bear with me. I've had my 2000 Limited for about 2 years, and I love it. I actually did some research on here to see what things I should look for, and I found a one with the multi-mode 4wd and the rear locker. I've done just a few little mods to it like the grey wire mod, '99 springs all around (1" higher), stereo with custom sub box, fat mat on all the doors (and door skins) and entire hatch area, and threw some 265/75 duratracs on.
I always liked the shrockworks plate bumper, but didn't have that kind of cash lying around. Then a couple months ago I fell asleep at the wheel, went off the road and hit tree. It mangled the bumper and front fender and broke a tie rod. Long story short(er), it was totaled, but totally fixable, so I kept it and got a check for 7600 (most of that went to the loan). So I decided to fix it myself and make a plate bumper for it.

 

[shaunredone]

Getting it back to how it was minus the bumper wasn't that bad. I have a buddy that's a painter, so I just bought a new fender, grill, headlight, and little filler piece, had them painted and put em on. I did have to massage the headlight support piece back into shape, but it wasn't too bad. All together I had $400 in to it to get it back to factory looking, just without the bumper.

 

[TheKorstjens]

Did the airbag not deploy?

 

[shaunredone]

I had looked at a bunch of plate bumpers and kinda had an idea of what I wanted to make. I basically took some of the design features I liked from shrockworks, 4xinnovations, the awesome bumper bandit made, and a few others, and put them together to make my own.
I got a 4x8 sheet of 3/16ths plate and got to work. I used a piece of plywood to get the top piece shaped how I wanted, then cut that out of steel. I cut the front plates off of the frame rails to weld in some nuts for more mounting holes(there will be 12 bolts that hold it on). I just used a flat piece of steel that connects the two frame rails as a winch mount. Then two vertical pieces against the outside of the frame rails that have the profile of the bumper cut out. These go all the way to the top piece and make a box at the front.

 

[shaunredone]

Since I cut the profile into the verticals, it was basically measure, cut, tack in place. I wanted it to be that easy on the corners too, so I cut another vertical profile piece and put them at the corners. It really made it pretty simple. Luckily my dad has about every tool known to man (he's a farmer), and so that means he has a 9" metal cutting circular saw. I had never used it, but it kicks ass! It's just like cutting wood, you just go slower, and you HAVE to wear hearing and eye protection. It's loud and throws a bunch of hot metal chips. But the cut edge is a mirror finish with no burrs at all (last 2 pictures)

 

[shaunredone]

Did the airbag not deploy?

The airbag didn't go off. It looks worse than it was, I wasn't even sore the next day

 

[Brique]

From the location of the damage, it looks like it was a glancing blow against that tree. Count yourself blessed, my friend.

This looks like it's gonna be awesome. Can't wait to see the finished product!

 

[shaunredone]

Well the front middle piece actually did take some time, but that's just because I wanted to flush mount my new led spotlights, and center up the hole for the fairlead. Then the others were pretty simple. Although the vertical pieces on either side of the center piece is just barely tacked in place, cause they have to come back off to flush mount my led floods (on backorder for a couple weeks) and turn signals. I think the turn signals are going to be sweet, not like any other ones I've seen, but you'll have to wait for that.

 

[White 4x4runner]

I love using the skill saws with a metal blade. Makes one nasty noise but it works so well. Bumper is lookin good so far but might I suggest beveling all the edges that your going to weld.

 

[shaunredone]

Well today was much nicer out, so I could open up the BIG door at dads new shop, and I could see much better! I finished up the little pieces and put the front lower on. The front lower has 2 bigger holes in it for a few reasons. I needed a place to put my hand in there to engage/disengage the winch clutch. I also had to have a way to adjust/aim my spot lights with the bumper on. They'll also let some air in to the radiator. And last but not least, I will be able to stick a hi-lift jack in either hole to jack the front up since it will be lifting from a much stronger vertical piece. The other 2 smaller holes are where the shackle mounts will come through (they aren't in yet either). So that's how its sitting as of today.

 

[1blink]

Looks pretty good so far man.

 

[TOY2G]

I'm not going to lie....I was expecting something different, but I think you are doing a great job. You may have inspired me to get in the shop and start mine.

 

[TNRunner99]

Very nice so far. Probably one of the best homemade plate bumpers I've seen around here.

 

[Bandit Runner]

That bumper is looking real good. Looks somewhat familiar though, I guess that's why I like it so much. :brushteeth:

 

[shaunredone]

Well, I've gotten quite a bit more work done on the bumper. When last I left I had it mostly tacked in place and was waiting on some lights and shackle hangers, but other than that it was ready to be fully welded. The shackle hangers came in, so I went to work. After about an hour welding and around 10 days grinding I had this.









It was around this point that I kinda forgot to keep taking pictures. After test fitting I decided that it needed another horizontal piece on the bottom to clean up the look from the side. I was still waiting on the lights, so I went ahead and made those pieces out of 1/8" to save weight, and welded them on. Then I made some side supports out of 1" round stock. Then waited some more for the damn lights. I have ordered a few things from superbrightleds.com and they have always been excellent quality, good price, with great customer service. But these flood lights that I've been waiting on is a different story. At first they said they were on backorder til 2/6, then it changed to 2/14, then 2/28, 3/7, now 3/14. :redbrick: So I decided to say F it, guess where they will be mounted and finish it up. So here it is getting primer.

 

[shaunredone]

Primered

 

[shaunredone]

And here it is mounted up, only missing the led floods, and a rubber seal that I'm going to put in between the bumper and body. I really like how the turn signals came out. They are about 10" long, 1/4" thick and are packed with 75 amber leds. The leds are on 1mm spacing, so close together that it looks like a very bright thin solid line when lit up.

 

[Granada7]

Yours is easily my favorite front plate of them all thought about ever selling those i love that design!

 

[dtc81]

Those turn signals are an awesome touch!

 

[Antman]

Very nice design and execution. Looks really good!:rockon: