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Old 01-24-2008, 07:25 PM   #1 (permalink)
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CAD Designed 3rd Gen Front Bumper Build - wjwerdna

So, it's been a while since I have read or posted on the forums, but since that time, I've come to the need of a new front bumper... I've done some destructive testing, for educational purposes of course...

So first, a pic of what I have been playing with while I work through the 10 degree weather and cold here with no garage...



actual work will be starting next week!
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Last edited by wjwerdna; 02-20-2008 at 06:48 PM. Reason: didnt like the title
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Old 01-24-2008, 07:27 PM   #2 (permalink)
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BE sure to take lots-o-pics.
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Suspension: Tundra TRD Fronts w/ Dual 3/8" "TerraBull" spacers: 2.5",Trekmasters, LC's/OEM LC Shocks: 3.5"...
Performance: 4" Deckplate, TrueFlow Air Filter, ISR Mod...
Shoes: 285/75/16 Nitto TG's, OEM 16x7 (6 spoke)...
Armor: Stubbs Sliders...
Exhaust: 18" Magnaflow SIDO, Magnaflow High-Flo Converter, 2.5" and 2.25" piping...
Other Necessities: Custom Extendable Panhard Bar, Custom Bumpstop Drop Brackets, 1" Diff Drop...
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Old 01-29-2008, 03:20 PM   #3 (permalink)
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First, if anyone ever wondered, this is how to make your bumper in 3D

Start with truck model (measured by hand):



Then add frame and start making it!

This is where I am at right now:
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Old 01-29-2008, 05:43 PM   #4 (permalink)
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Sorry, I realize this isn't as fun as pictures of actually cutting into it

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Old 01-29-2008, 09:19 PM   #5 (permalink)
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are you using solid edge?


thats a pretty good model
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Old 01-29-2008, 10:40 PM   #6 (permalink)
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no, I used to use SolidEdge years ago, then UG, then SolidWorks, now Inventor
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Old 02-02-2008, 08:56 PM   #7 (permalink)
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Ready... Set... Almost there

Ok, so I'm ready to start getting this going, tomorrow I am going to start cutting the smaller pieces. Monday-Wednesday should be able to get the rest of the steel, then onto getting it ready to bolt up. chopping the frame, and finishing it all up!!! With all the cold weather, I've had enough time to plan out everything on paper first, actual building should go very smooth



click pics for larger!
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Old 02-02-2008, 09:05 PM   #8 (permalink)
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WOW. Hello Mr. CAD expert. How long did that take? I took a Advanced CAD class in HS but the fat teacher was to lazy to teach.
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Old 02-02-2008, 09:24 PM   #9 (permalink)
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Quote:
Originally Posted by dirtbiker13575 View Post
WOW. Hello Mr. CAD expert. How long did that take? I took a Advanced CAD class in HS but the fat teacher was to lazy to teach.
lol, thanks =) It's fun to work with this software, and I get to use it a bit at work when I get a chance

I would say so far I have about 5-7 hours in actual measuring and sketching the 4runner body and frame in 2D, with another 3-4 hours to correctly model/extrude/shape and color it. Then quite a bit of time so far developing all of the bumper, brackets, etc.. probably 12-15 hours. Then another 2 hours finishing it up and creating all the separate print views to make each part For the most part I am done with the CAD part, so I would guess 20-30 hours total? maybe more.
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Old 02-02-2008, 09:45 PM   #10 (permalink)
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cool stuff. where are the turn signals going to be? I like how you have the larger lights incorporated into the bumper.
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Old 02-03-2008, 07:32 AM   #11 (permalink)
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Quote:
Originally Posted by Godzilla View Post
cool stuff. where are the turn signals going to be? I like how you have the larger lights incorporated into the bumper.
the turn signals have allready been wired into the lights next to the headlights using higher wattage 2-filament bulbs
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Old 02-03-2008, 10:45 AM   #12 (permalink)
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Wow, great work! I wish I knew how to use my SolidEdge like that! What do you do for a living?

Keep us updated!
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Old 02-03-2008, 12:44 PM   #13 (permalink)
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Quote:
Originally Posted by Atomic View Post
Wow, great work! I wish I knew how to use my SolidEdge like that! What do you do for a living?

Keep us updated!
I'm a mechanical engineering student, almost done with studies (1 year left)... I just started using this software (ACad Inventor) but it is pretty much the same as others, very similar to SolidWorks. All it takes to learn is to sit down and really work with the software =)

I started work cutting brackets and little pieces today, some progress at least tomorrow is a trip to the steel warehouse
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Old 02-16-2008, 05:04 PM   #14 (permalink)
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Looks sweet so far, it's coming together pretty good. a dozen grinding/cutting disks so far
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Old 02-16-2008, 05:25 PM   #15 (permalink)
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Looks great so far. What are you using for grinding discs? I work for the largest manufacturer of such products in the world. I may have some stuff hanging around that you could use.
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Old 02-16-2008, 05:53 PM   #16 (permalink)
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Good looking. Looks like it'll be solid. I like the indents for the lights. I'm thinking of something similar. Keep us updated.

I've always had good luck with Norton disks. I bought some cheap HF disks, what junk. It was the closest place, should have driven further for the Nortons.
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Old 02-16-2008, 05:56 PM   #17 (permalink)
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Quote:
Originally Posted by dirtbiker13575 View Post
WOW. Hello Mr. CAD expert. How long did that take? I took a Advanced CAD class in HS but the fat teacher was to lazy to teach.
Same here my teacher sucked

Looks great I wish I had some of that software it could come in handy
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Old 02-16-2008, 07:35 PM   #18 (permalink)
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Wow-nice build. I too like the inset lights. Are you planning on marketing the bumper once complete?
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Old 02-16-2008, 11:50 PM   #19 (permalink)
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Quote:
Originally Posted by fillsrunner4 View Post
Same here my teacher sucked
Looks great I wish I had some of that software it could come in handy
The teacher doesn't matter... ever, it is how you apply yourself

Quote:
Originally Posted by Whitey13 View Post
Looks great so far. What are you using for grinding discs? I work for the largest manufacturer of such products in the world. I may have some stuff hanging around that you could use.
I have bought an assortment of dewalt 1/16" cutoffs, a Bosch grinding disk that came with grinder (longest lasting so far), a "gator grit", and an assortment of other ones from TSC

Quote:
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Wow-nice build. I too like the inset lights. Are you planning on marketing the bumper once complete?
Lol, I thought about it, but as of now, no. The plans/components/build details will not be available to anyone for free or purchase. Sorry
I have put too much time into the design for the plans to be affordable.

EDIT: My friend and I are contemplating the idea of marketing these bumpers "for off-road use" of course (due to implications of safety tests for roads). We are thinking about the possibility of fully customizable bumpers, with a "you name it, we make it style." We would try to keep the cost down, but truly it wouldn't be the cheapest out there, but could still be affordable, we don't have the time or resources to stock steel and materials in large quantities to get discounts.

More pictures and details should be up end of Sunday, there is a lot more work to do, finish all welds, add front portions, a little more trim work, mount lights, clean-up, sandblast, paint, etc
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Old 02-17-2008, 09:17 AM   #20 (permalink)
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Wow! Looks amazing so far. Keep up the great work!
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Old 02-17-2008, 07:01 PM   #21 (permalink)
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Sad day, my camera was dead, and we made a lot of progress I wanted to share. Bumper needs a couple pieces of trim, some mounts for fog lights, and final sanding, the whole thing is welded and ground smoothish. It's looking pretty good, hoping to have it finished this week/next weekend
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Old 02-17-2008, 08:22 PM   #22 (permalink)
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sweet-can't wait to see the pics!
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Old 02-18-2008, 01:17 PM   #23 (permalink)
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I have bought an assortment of dewalt 1/16" cutoffs, a Bosch grinding disk that came with grinder (longest lasting so far), a "gator grit", and an assortment of other ones from TSC

What diameter are you using?
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Old 02-19-2008, 07:29 PM   #24 (permalink)
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What diameter are you using?
it's a 5" grinder, so one that came with it was 5" but 4.5" is cheaper, so ive been buying those
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Old 02-19-2008, 07:39 PM   #25 (permalink)
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Ready for some more pictures?

Got the rest of the welding/grinding done, rough sanded everything, needs a bit more sanding work still...




click for larger





ran out of propane for the heat, so called it a night, later this week is sandblasting and painting
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