Another 3rd Gen Front Bumper Build - wjwerdna

wjwerdna · 01-24-2008, 07:25 PM

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!

This ad is not displayed to registered members.
Register your free account today and become a member on Yotatech!

Nate08 · 01-24-2008, 07:27 PM

BE sure to take lots-o-pics.

wjwerdna · 01-29-2008, 03:20 PM

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:

wjwerdna · 01-29-2008, 05:43 PM

Sorry, I realize this isn't as fun as pictures of actually cutting into it

Tylerars24 · 01-29-2008, 09:19 PM

are you using solid edge?

thats a pretty good model

wjwerdna · 01-29-2008, 10:40 PM

no, I used to use SolidEdge years ago, then UG, then SolidWorks, now Inventor

wjwerdna · 02-02-2008, 08:56 PM

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!

toylocost · 02-02-2008, 09:05 PM

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.

wjwerdna · 02-02-2008, 09:24 PM

Quote:

Originally Posted by dirtbiker13575

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.

Godzilla · 02-02-2008, 09:45 PM

cool stuff. where are the turn signals going to be? I like how you have the larger lights incorporated into the bumper.

wjwerdna · 02-03-2008, 07:32 AM

Quote:

Originally Posted by Godzilla

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

Atomic · 02-03-2008, 10:45 AM

Wow, great work! I wish I knew how to use my SolidEdge like that! What do you do for a living?

Keep us updated!

wjwerdna · 02-03-2008, 12:44 PM

Quote:

Originally Posted by Atomic

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

wjwerdna · 02-16-2008, 05:04 PM

Looks sweet so far, it's coming together pretty good. a dozen grinding/cutting disks so far

Whitey13 · 02-16-2008, 05:25 PM

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.

Gerdo · 02-16-2008, 05:53 PM

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.

fillsrunner4 · 02-16-2008, 05:56 PM

Quote:

Originally Posted by dirtbiker13575

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

bruzer1123 · 02-16-2008, 07:35 PM

Wow-nice build. I too like the inset lights. Are you planning on marketing the bumper once complete?

wjwerdna · 02-16-2008, 11:50 PM

Quote:

Originally Posted by fillsrunner4

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

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:

Originally Posted by bruzer1123

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

Atomic · 02-17-2008, 09:17 AM

Wow! Looks amazing so far. Keep up the great work!

wjwerdna · 02-17-2008, 07:01 PM

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

bruzer1123 · 02-17-2008, 08:22 PM

sweet-can't wait to see the pics!

Whitey13 · 02-18-2008, 01:17 PM

Quote:

Originally Posted by wjwerdna

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?

wjwerdna · 02-19-2008, 07:29 PM

Quote:

Originally Posted by Whitey13

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

wjwerdna · 02-19-2008, 07:39 PM

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

01-24-2008, 07:27 PM	#2 (permalink)
Nate08 Registered User Join Date: Jul 2007 Location: Bristol, TN Posts: 647	BE sure to take lots-o-pics. __________________ Nate [/font] 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...

01-29-2008, 03:20 PM	#3 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	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: __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

01-29-2008, 05:43 PM	#4 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	Sorry, I realize this isn't as fun as pictures of actually cutting into it __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

01-29-2008, 09:19 PM	#5 (permalink)
Tylerars24 Registered User Join Date: Aug 2007 Location: On top of your wife. Posts: 127	are you using solid edge? thats a pretty good model __________________ pickup, sas, 63s, custom high-steer

01-29-2008, 10:40 PM	#6 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	no, I used to use SolidEdge years ago, then UG, then SolidWorks, now Inventor __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

02-02-2008, 08:56 PM	#7 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	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! __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

02-02-2008, 09:05 PM	#8 (permalink)
toylocost Registered User Join Date: Jul 2007 Location: Yotatech, because Pirate is too expensive. Posts: 1,428	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. __________________ 1982 2wd Pickup - Custom Interior - Pioneer 8" subs 1990 4runner - Blown Head Gasket Mod (fixed!) - Cruiser Coils - BJ Spacers - Bed Lined Fenders - CB/PA - Alpine HU - H4 Headlights - 2 15s and a Rockford amp. 1996 Camry - 400,000 miles on original engine/transmission. HELL YES!!! All it takes is a quart of oil with every tank of gas. Project: scratch building a modernized Lotus 7 replica using a 22-re Celica drivetrain

02-02-2008, 09:45 PM	#10 (permalink)
Godzilla Registered User Join Date: Mar 2004 Location: Vancouver Posts: 2,151	cool stuff. where are the turn signals going to be? I like how you have the larger lights incorporated into the bumper.

02-03-2008, 10:45 AM	#12 (permalink)
Atomic Registered User Join Date: Jul 2007 Location: Crystal Lake IL (Home) or Oxford OH (MU Ohio) Posts: 317	Wow, great work! I wish I knew how to use my SolidEdge like that! What do you do for a living? Keep us updated! __________________ Tess- 1998 4Runner 4WD SR5: 154k, Evergreen Pearl Metallic, ARB Tacoma Bull Bar, Hella 500's, Deckplate, ISR, WabFab discos, 5.25'' Infinity Reference rears, Baja amp powering a 10'' Infinity Reference sub, Sylvania Silverstars, JB L.E.D. Taillights 1996 4Runner 2WD SR5: stock, dented, almost dead, 207k- Brother's

02-16-2008, 05:04 PM	#14 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	Looks sweet so far, it's coming together pretty good. a dozen grinding/cutting disks so far __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

02-16-2008, 05:25 PM	#15 (permalink)
Whitey13 Registered User Join Date: Jan 2006 Location: MA Posts: 1,115	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.

02-16-2008, 05:53 PM	#16 (permalink)
Gerdo Registered User Join Date: Nov 2005 Location: SouthWest Littleton, Colorado Posts: 842	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. __________________ 2000 4Runner Sport, 3.4L, 5 Speed, Custom Front Winch Bumper, Opened intake, K&N Airfilter, BFG A/T LT265/70R16, Bilstein Shocks, FreeFlow Exhaust, Poly Rack Mounts & Swaybar Mounts, Tundra TRDs up front and OME 891s out back. ToyTec Panhard Bar Drop. SS Front Diff Drop. Home-built 2x2 Sliders. ARB rear locker, OBA, CO2 See My 4Runner!

02-16-2008, 07:35 PM	#18 (permalink)
bruzer1123 Registered User Join Date: Feb 2005 Location: Idaho Posts: 337	Wow-nice build. I too like the inset lights. Are you planning on marketing the bumper once complete? __________________ 1993 Pickup 22RE 4x4 5 spd. Mods: Engnbldr Street RV Head with 261 C, Trueflow air filter, custom rear bumper, roof rack, 2.25 exhaust from cat back, Thrush muffler, Rancho 5000 shocks, tiny MTRs Future Mods: Diff breathers. Rear locker? Winch? OBA? Flatbed?

02-17-2008, 09:17 AM	#20 (permalink)
Atomic Registered User Join Date: Jul 2007 Location: Crystal Lake IL (Home) or Oxford OH (MU Ohio) Posts: 317	Wow! Looks amazing so far. Keep up the great work! __________________ Tess- 1998 4Runner 4WD SR5: 154k, Evergreen Pearl Metallic, ARB Tacoma Bull Bar, Hella 500's, Deckplate, ISR, WabFab discos, 5.25'' Infinity Reference rears, Baja amp powering a 10'' Infinity Reference sub, Sylvania Silverstars, JB L.E.D. Taillights 1996 4Runner 2WD SR5: stock, dented, almost dead, 207k- Brother's

02-17-2008, 07:01 PM	#21 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	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 __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

02-17-2008, 08:22 PM	#22 (permalink)
bruzer1123 Registered User Join Date: Feb 2005 Location: Idaho Posts: 337	sweet-can't wait to see the pics! __________________ 1993 Pickup 22RE 4x4 5 spd. Mods: Engnbldr Street RV Head with 261 C, Trueflow air filter, custom rear bumper, roof rack, 2.25 exhaust from cat back, Thrush muffler, Rancho 5000 shocks, tiny MTRs Future Mods: Diff breathers. Rear locker? Winch? OBA? Flatbed?

02-19-2008, 07:39 PM	#25 (permalink)
wjwerdna Contributing Member Join Date: Mar 2006 Location: Novi, MI Posts: 1,866	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 __________________ Andrew J W = WJwerdnA '99 4Runner SR5 - Pioneer MP3/IPod w/Infinity all around - lifted 2.5-3in susp. - 33's to fill the gap - sliders - ISR & Deckplate, yada yada - Satoshi - AIM:wjwerdna YotaTech Profile Custom Bumper Link for sale: ??? Nothing?

Thread Tools	Search this Thread
Show Printable Version Email this Page	Search this Thread: Advanced Search

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
3rd gen 4runner Custom front bumper build	crolison	The Fab Shop	30	08-22-2009 01:29 PM
3rd gen. 4runner front bumper build	T-town	The Fab Shop	29	10-29-2007 10:39 PM
Front Bumper Build 3rd gen with stinger MERRY XMAS HEATH!	BOSTON4RUNNER	The Fab Shop	26	01-27-2007 01:33 PM
3rd Gen bumper build....Again	HarrisonP	The Fab Shop	3	11-27-2006 07:21 AM