Pelfreybilt Winch Bumper woes...

[rickashay]

I have an 05' 4Runner with the PB Aluminum front bumper. I also have a 06-09' grille that I have been wanting to swap but ran into the grille fitment issues with the bumper and just haven't made the cut yet (like you have) to make it fit. It indeed looks like you got the 03-05' version for sure. Thanks for showing the markings & cut for the newer grille, this will help me in my endeavours once I find the time to do the grille swap.

I also have slight fitment issues like others have stated. I have shimmed the top mounting point outward to try and correct the tilt that seems to be built into these bumpers. As others have stated it's a work in progress and could be better, but itsn't terrible. I installed my bumper solo and ended up with a small amount of left/right tilt but I think that's because I struggled holding it up (with winch pre-installed) while I tightened everything down. lol That was a struggle.

I "massaged" my A/C line but after 4 months or so of driving it rattled itself on the edge of the bumper and wore through my line. I have to replace the line ($$$$) and when it was re-installed I had it wrapped in rubber (as others have stated) and have not had any issues now in the last 1.5-2 years.

I explored the same powdercoating idea as you, but ended up going with paint as my top priority was getting it color matched. I had the paintshop ad a couple extra layers of both paint and clearcoat knowing that is it not quite as durable as powdercoating. That being said, over two years later and it's not rusting and still looks great except for the odd rock chip. Plus I can use my Toyota touch-up paint pen to dab any small chips.

This is mine, taken last week. Approx 40,000kms of year round driving and 2 years after having the bumper painted.

EDIT: you can see I still could use a little more forward tilt on the bumper angle as well. It's currently spaced forward on the top stud about 1/4"


_08I1131.jpg by Addison Rickaby, on Flickr

 

[Hwy88-Taco]

Elongated shakedown successful!

1.5 yrs later and the finished product has gone through the shakedown test successfully. By shakedown I mean 2K mi from The Bay to The Cascades and back. As well as a few Sierra weekends to boot. I’m very sorry for ditching you guys. You’ve all been so helpful and encouraging.

After I received the winch I revised my plan for the front receiver with a long threaded pin that comes in from the drivers side. Works perfectly and much less complicated that my initial plan. I reworked the release lever to the left of the initial position. Instead of the lever being under the grill it is now in the first pocket above the bumper.

I also mounted the cylinoid/switch pack remotely to the radiator support, though after thought, I don’t think it was necessary. It looks like there would have been plenty of clearance on top of the winch.

I followed your suggestions for massaging the a/c line also finessed the power steering lines on the side of the frame. 2.5Kmi (4-500mi 4low trails) No chaffing or rubbing of paint or lines (tires are a different story).

Rustoium truck bed coating on the back and Rustolium white on the front +2 coats of clear. There’s a few rock chips but I now can touch-up very easily.

Any questions just fire away. I took plent more pics and I’m happy to take more if you’re courios. Happy to help since y’all have been so helpful.