ARB Bumper install from HELL
 

Ok, so here is the scoop. I am currently running a 2" RB spacer body lift, and have wheeled the soup outta the truck. It was finally time for a clutch and new front brakes. While I was going to have the front end apart to do the brake job, i figured it was time to throw a TC LT kit on as well and hell, a bumper is only a couple additional frogskins when it comes down to it. So I bought a bumper from TRDparts4U at the same time I purchased the clutch.

As we all know it SHOULD be a simple bolt in procedure, just my luck... it isnt. On the LHS when you take the crush cans and bumper off and then install the ARB mounting block and sump guard the bumper bracket is a good 1/4" from meeting up with the tow hook mounting holes. That isn't a huge deal, I just need to drill out the bracket holes and mount the critter on there. The RHS is a completely different issue. My factory snatch hook was mounted on this side and I came down on it at some point hard enough to bend the bottom of the frame in the center of that little span. My buddy suggested heating the area, shoving a bolt in there and then hammering on the bolt to attempt to get the frame down where it should be. In the process the rear welded nut for the hooks and tie straps snapped off of the frame (it looks like a cold weld). So... what do you guys think I should do? Through drill and add a plate to the top out of angle to help distribute the weight? Remember the body mount is up there as well so there isn't a level spot and it would need some fill weld, or drill out the holes a bit more and try to shove a bolt in there all cattywhompus?

By the way, why does ARB want you to through drill their blocks and shove a bolt through there? It doesn't look like it provides any additional stability. You are drilling through a block that has the 17mm bolt going into the end caps of the frame...

When I had an ARB on my taco I never drilled through the block..I used the stock endcap bolts for the endcap, and the new bolt for the front of the block. Shouldn't have to drill anything with the taco install. On my 4runner you do have to drill through the frame to insert that huge bolt. Leave the huge bolt in the parts bag incase you get a 4runner someday ;).

Not sure about your tweaked tow hook mounts. Can you get 1 of 2 bolts to anchor the bottom of the mount?

Maybe you could weld the mounts on and just put your welds where you could grind them off later if you ever wanted to remove it. If you did this, just make sure the frame rails are straight enough with the mounts attached to accept the bumper, you won't be able to make any adjustments once it's welded.

I ended up simply cutting some meat out of the ARB mounting bracket and was able to get one of the bolts in on the passenger side. On the driver's side everything went together as planned. Thanks for the suggestions!