Rubicon Trip Report - AND Minimalist Rear Bumper Protection (Bolt On)

[Jetboy]

I like it, ought to help. You going to nix or trim the mud flaps before you go? What about a skid for the exhaust crossover pipe? Kudos to you for taking on the Rubicon in a stockish 4Runner, look forward to seeing a trip report!

I added a skid for the crossover and transfer case output a few years ago. That was the first skid I added because it's so low. I'll see if I can dig up the thread about it. I also added a transmission skid for this trip. That was super easy to fab. just a flat sheet of steel with some holes and two lengths of 2x2 angle welded on for rigidity.

 

[1engineer]

You must be a much better driver than me I like my truck too much but good luck. Please post pics of the aftermath!

It's always 90% driver. I've been places and witnessed vehicles that absolutely should not be where they are, but got there by skilled drivers.

 

[Jetboy]

Really cool setup. Are you on MUD? I'd love to read a build thread of your 40... :bigok:

I am. But it's been a LONG time since I built it. Over 10 years. It's on my short list of projects to get back to. I've been really itching to get back into a dedicated trail rig, but I don't have enough parking for all my toys. This is going to sound crazy - but I've been very seriously considering building a tube frame from scratch - basically like a giant side by side - and running Lexus RWD based IFS/IRS with 37-40" tires and moving to a mid or rear engine setup with a smallish 4cyl and transaxle from a Yaris/Scion. The goal would be a re-build under 2,000lbs. I have built one UTV chassis with a few friends for an engineering demonstration that you can epoxy frame members together rather than weld them, so it's not my first rodeo, but it's a major commitment if I go that route.

Otherwise I'll probably find a nice donor vehicle - either a 6MT tacoma, or possibly a 1UZ as a swap and drop the ride height down to something more reasonable. Plus I'd like to extend to about a 110" wheelbase. Short tall vehicles are really ideal in Montana where I'm from. But living in Utah it's the opposite of what you want here.

As it is now, it's pretty much the standard FJ40 build. I stripped and repainted the body yellow. Put Honda Prelude seats and a 6 point cage in it. Went SOA with Old Man Emu 2.5" springs. 5.29 gears. Lockers. Front and rear double cardain driveshafts, HEI conversion, York OBA, custom build ARB style front bumper with a Warn 8274, 15x12 wheels with 39.5 TSLs, and Saginaw power steering. I've also switched to a race style toggle switch and push button start - no keys needed (but there is a very tricky ignition lockout, so it's very hard to steal). Oh - and disk brakes from a mini-truck along with cut and turned knuckles for around 5* of castor. I made the quarter panel rust covers out of brushed stainless rather than aluminum. It was never going to be a show truck - but I would probably replace the entire tub if I were doing it again with a new one. And choose something other than that god awful Ford Lightning yellow. WTF was I thinking? That's pretty much it.

I built it when I was 20 though, so the quality of work is not great. I didn't have patients or the income I have now. So I did a lot of things cheaply and quickly that aren't pretty. If I re-build it I'll do a ton of things differently and fix a lot of past sins.

 

[Hellaflushfj60]

Sounds like a sweet rig nonetheless. I'm about to order a Saginaw kit myself. A fiberglass tub would be sweet for weight savings, especially if you're running a cage around it so it won't get beat up. Look forward to your future build. Cheers

 

[Jetboy]

Sounds like a sweet rig nonetheless. I'm about to order a Saginaw kit myself. A fiberglass tub would be sweet for weight savings, especially if your running a cage around it so it won't get beat up. Look forward to your future build. Cheers

Thanks. Sorry for the long winded response. Can you tell I'm internally conflicted on whether I want to commit to re-building it? lol.

 

[Scharfschütze]

Cool thought and looks well made but that is going to reduce rear depart angle quite a bit. I have never been to Rubicon but I have bashed the CRAP out of my OEM rear bumper getting over some moderate terrain, and I'm fairly well lifted.

I hope its easy to remove on the trail, I could see that hanging you up quite a bit in some instances. Good luck!

 

[WVSR5P17']

I'm headed to run the Rubicon tomorrow - and I had been planning some extra skid protection. Mostly the rear bumper is the primary spot. I also built a transmission skid and upgraded the OEM gas tank skid (I just cut the same pattern in 10 guage steel plate and welded it to the OEM gas tank skid (about 30 spot welds), then drilled the drain holes. It's not pretty - but it'll be functional. I only had 1 day to build all of these skids.

So... long winded intro, but this is what I came up with in about 4-5 hours. Bolts on to existing anchor locations plus two more locations approx 18 further forward on the lower frame rail. Protects the OEM exhaust location well (I don't like side exit because I've already ripped off both mud flaps and teh bottom of each side bumper have taken abuse already. A side exit would have a very short lifespan on my 4runner. The rear exist already is there, and IMO is easier to protect.

My intention is to add one final plate that will cover the spare tire all the way to the bar in the middle with a cutout for the trailer hitch, but I ran out of time. And I didn't have my CNC Plasma table setup, so this was all done by hand. Just a time problem. When I get some time I'll add the plate. It'll be a bolt on addition that goes on after you install the other portion. IT should take about 15 minutes to install and remove. I probably will not leave it on for daily driving.

I think it looks pretty sweet. You did a good job from the pictures. I would buy a set lol


Sent from my iPhone using Tapatalk

 

[JSparky]

Godspeed, I'd come up in my 80 but I'm nursing a broken leg right now.

 

[wfo9]

I wish I could come run it with you.. but I would probably much rather be in my trail rig and relaxed.... LOL

Anyway, I like the minimalist bumper work.

I would have considered just taking the cover off for the trip and running some protection on the corners and let the steel bumper take the hits.

Similar to what I did except mine is all welded on. Mine works really well. I have the plastic parts bolted to the actual steel bumper so it can't rip off. I've dragged it many times with no issues. I plan to eventually cut it off all the way up to the deck and then run another tube just to give it some aesthetics. I much prefer function over form. Big heavy swing outs are not ideal for an already heavy pig. I would like to get the tire up and out of the way, but the weight is nice down low...

I run a pizza cutter spare now, so the tire sits up higher and is still close enough to my tire to run.

 

[Jetboy]

I wish I could come run it with you.. but I would probably much rather be in my trail rig and relaxed.... LOL

Anyway, I like the minimalist bumper work.

I would have considered just taking the cover off for the trip and running some protection on the corners and let the steel bumper take the hits.

Similar to what I did except mine is all welded on. Mine works really well. I have the plastic parts bolted to the actual steel bumper so it can't rip off. I've dragged it many times with no issues. I plan to eventually cut it off all the way up to the deck and then run another tube just to give it some aesthetics. I much prefer function over form. Big heavy swing outs are not ideal for an already heavy pig. I would like to get the tire up and out of the way, but the weight is nice down low...

I run a pizza cutter spare now, so the tire sits up higher and is still close enough to my tire to run.

That looks great!

 

[FactoryRide]

I wish I could come run it with you.. but I would probably much rather be in my trail rig and relaxed.... LOL

Anyway, I like the minimalist bumper work.

I would have considered just taking the cover off for the trip and running some protection on the corners and let the steel bumper take the hits.

Similar to what I did except mine is all welded on. Mine works really well. I have the plastic parts bolted to the actual steel bumper so it can't rip off. I've dragged it many times with no issues. I plan to eventually cut it off all the way up to the deck and then run another tube just to give it some aesthetics. I much prefer function over form. Big heavy swing outs are not ideal for an already heavy pig. I would like to get the tire up and out of the way, but the weight is nice down low...

I run a pizza cutter spare now, so the tire sits up higher and is still close enough to my tire to run.

Do you have any measurements of the tube bends? I'd like to do something similar since I've decided to hold off on a rear bumper for the time being.

That looks great!

How did it go?

 

[STX4Runner]

I love this, been thinking about something like this for a long time. Unfortunately I don't know how to weld, nor do I have the tools. I remember [MENTION=106176]wfo9[/MENTION] and his bumpers too. I like the minimalist, lightweight approach. In the end, I realized it's probably cheaper to just wheel the piss out of the stock bumpers and replace them if I have too. The black plastic of the old body style 5th Gens takes a lot of abuse and does not show scratches easily. I can beat these up 'till I can't stand it and replace them with new OEM for way cheaper than a metal bumper. I got rear ended a few years ago and the only damage was the stock bumper. It was about $1,000 to get it replaced. I even thought I could save the beat up bumpers for use as strictly off roading bumpers, as I only go about once a year, but when I do it's for a big trip to Moab usually. [MENTION=118321]Jetboy[/MENTION], definitely post pics and a writeup of the Rubicon.

 

[Jetboy]

I don't have time to do a write-up at the moment, but maybe tomorrow or the next day. It went great. I had a great time. It's probably more than I should have done in my daily driver. And apparently it's pretty time dependent - if you go after the jeep jamboree in the fall it's a lot easier than in the spring (they use a team of people to stack rocks and make the trail easy for the jeepers), and this year with all the snow quite a few obstacles got re-arranged. So if you want to go the easiest time, don't go on the first run of the season (like this one).

I made it through almost totally clean. A few minor plastic scratches. And I beat the piss out of the skid plates all around. The sliders slid and the winch winched a lot too.

I also had a fantastic group that really did a great job of helping get through unscathed. There were a few lines where I would have chosen a completely different path and the trail leader of our wagon run spotted something that looked totally wrong. I thought he was crazy, but he had done every other obstacle perfectly so I followed his spot and sure enough it was just the right line. Going with a group of experienced Rubicon folks made a HUGE difference. Hat's off to them!

Anyway here's a teaser picture of one tight squeeze going into the big sluice. This is a tricky squeeze, but probably about a 6 out of 10 compared to other spots. The Rubicon is basically non-stop obstacle from the gate keeper to Tahoma, so I didn't have time to take many pictures. I'll post more tomorrow.

 

[wfo9]

I don't have time to do a write-up at the moment, but maybe tomorrow or the next day. It went great. I had a great time. It's probably more than I should have done in my daily driver. And apparently it's pretty time dependent - if you go after the jeep jamboree in the fall it's a lot easier than in the spring (they use a team of people to stack rocks and make the trail easy for the jeepers), and this year with all the snow quite a few obstacles got re-arranged. So if you want to go the easiest time, don't go on the first run of the season (like this one).

I made it through almost totally clean. A few minor plastic scratches. And I beat the piss out of the skid plates all around. The sliders slid and the winch winched a lot too.

I also had a fantastic group that really did a great job of helping get through unscathed. There were a few lines where I would have chosen a completely different path and the trail leader of our wagon run spotted something that looked totally wrong. I thought he was crazy, but he had done every other obstacle perfectly so I followed his spot and sure enough it was just the right line. Going with a group of experienced Rubicon folks made a HUGE difference. Hat's off to them!

Anyway here's a teaser picture of one tight squeeze going into the big sluice. This is a tricky squeeze, but probably about a 6 out of 10 compared to other spots. The Rubicon is basically non-stop obstacle from the gate keeper to Tahoma, so I didn't have time to take many pictures. I'll post more tomorrow.

:whoo:
Bad ass.. and well done!. I love stuff like this. Sounds like it was a blast overall. Wish it was not such a long drive for me.... I'm going to do it next year one way or another.

It makes such a difference having those familiar with the trail and lines along to guide. Even the best instincts are just wrong sometimes.

Can't wait to hear and see more.

I bet people were amazed a pretty mild 5th gen was out there doing it...

Congrats.

 

[ds4runner]

Awesome!!!! I cant wait to see the rest of the pics. BTW what hidden bumper winch are you running (mount and winch)?

 

[007Tacoma]

So looking forward to more pics of this adventure. Also, I would love to see a pic of the bumper protection off the 4R.

 

[wfo9]

Do you have any measurements of the tube bends? I'd like to do something similar since I've decided to hold off on a rear bumper for the time being.

No, don't remember the numbers... It is less than 90 and greater than 45 LOL.... 1 3/4 DOM tube done with a standard die that I think was 5.25" center line radius. The very corner of the plastic cover hangs over a tiny bit. I was going to cut and weld in a small plate with a gusset on top to protect it and square off that corner.. but never got around to it and have never had a problem with it catching on anything.

I think rear bumpers on these trucks really impact overall performance in a negative way. They are fantastic utility and convince with the swing outs... but you really can't do anything worse for suspension dynamics than cantilever weight on the ends...

I ran without a front plate/winch bumper for a long time.. and could really feel the difference when I finally added one. The clearance was totally worth it.. but boy could I feel the weight. Anyone who tells you weight can simply be made up for with stiffer springs.. is misguided. Sprung weight absolutely impacts everything. You have to decide between utility and performance. Aluminum is also a good option. but price and durability take a hit...

 

[FactoryRide]

No, don't remember the numbers... It is less than 90 and greater than 45 LOL.... 1 3/4 DOM tube done with a standard die that I think was 5.25" center line radius. The very corner of the plastic cover hangs over a tiny bit. I was going to cut and weld in a small plate with a gusset on top to protect it and square off that corner.. but never got around to it and have never had a problem with it catching on anything.

I think rear bumpers on these trucks really impact overall performance in a negative way. They are fantastic utility and convince with the swing outs... but you really can't do anything worse for suspension dynamics than cantilever weight on the ends...

I ran without a front plate/winch bumper for a long time.. and could really feel the difference when I finally added one. The clearance was totally worth it.. but boy could I feel the weight. Anyone who tells you weight can simply be made up for with stiffer springs.. is misguided. Sprung wight absolutely impacts everything.

Yeah I get where you're coming from. I've decided to hold off on a rear bumper for the time being. There's not really 1 single bumper that fits all of my needs/wants. I do like the idea of a little additional departure angle on the rear corners though. I cave mine in about once a trip.

I've got a tire carrier that I built, which was one of my primary needs of a bumper, but now that I've got that covered, I just need a little more departure.

 

[wfo9]

Yeah I get where you're coming from. I've decided to hold off on a rear bumper for the time being. There's not really 1 single bumper that fits all of my needs/wants. I do like the idea of a little additional departure angle on the rear corners though. I cave mine in about once a trip.

I've got a tire carrier that I built, which was one of my primary needs of a bumper, but now that I've got that covered, I just need a little more departure.

Yep, I smashed the corners constantly, and that was the entire reason for what I did. It made a huge difference. To the point where I'm almost never have to worry about what the rear is doing anymore (unless it is just crazy steep). My friend who I wheel with quite a bit has the 4x4 labs rear bumper. We have about the same clearance except for my hitch occasionally dragging. If I took that off and exposed the bare cross member, we would be pretty much identical in real world scenarios.

 

[bimrunner]

Nice! It's a fun trail. Rubithon? Wagon run with Andy guiding? Did they blow up the boulder off of Cadillac hill? Wish I was there this year...