3rd gen. 4runner front bumper build
 

I started a new front bumper a couple weeks ago and have been working on it here and there. Just though I would post some pics and maybe get some feedback, its not quite finished yet. Everything is tacked on right now. tomorrow...errr...today my neighbor who is a certified welder is gonna come by and lay down some nice beads:)

http://i146.photobucket.com/albums/r...mper/0003a.jpg
Getting it prepped

http://i146.photobucket.com/albums/r...mper/0004a.jpg
Starting to eyeball the bends

http://i146.photobucket.com/albums/r.../IMG_0049a.jpg
main tube tacked on

http://i146.photobucket.com/albums/r...Bumper/53a.jpg

http://i146.photobucket.com/albums/r...mper/0051a.jpg
main tube need to be rotated up but i can fix that before we weld it

http://i146.photobucket.com/albums/r...MG_0054a-1.jpg
bottom hoop mounted

http://i146.photobucket.com/albums/r...r/bumper1a.jpg

everything ready to go. All tubing is HREW 1.75 x .120 tubing. I wanted to keep the front bumper as light as possible because I'll be putting a TC long travel kit on and mashing around in the desert as well as trails in tahoe and Bozeman. I want to make a high lift mount for it which will probably be my project tomorrow. Also I will be adding a hoop on top of the main tube to protect lights and a 1/4 inch aluminum skid plate.

Lookin good!

Its all welded together now. I was thinking of doing 1/4" 6061 aluminum skid plate. Or does someone have a better idea??? thanks

looks nice wish i had tools to fab stuff

I love people like you! Keep the pics and progress coming...i'm sure they will help MANY others in the future. So far it's looking really nice.

i can't finish the skid plate till I get back to school because the aluminum has to be ordered and it won't get to Reno before I leave. Finished product should look very similar to the camburg 4runner's bumper. I'll try to get some pics...

http://www.camburg.com/images/xVehi/4Runner/Front.jpg

Camburg 4runner

Also how do you guys notch tubes? We just started using a technique where you make two diagonal cuts like so:
http://i146.photobucket.com/albums/r...enotching1.jpg

it works pretty well with a little grinding and is super quick. You can make different angles by making one side longer or shorter.

T Town, Looks great. Nice job.

looks sweet cant wait to i get the pipe to start mine

Nice work dude! I love stock trucks that forgo euro tail lights and other bling and fab up a gnarly bumper.

looks good!!

actually I have Donahoe coilovers, OME N86 shocks, OME 891 coils, and TC UCA's. I wish I had time to finish my front bumper right now and start my rear bumper and sliders. I just painted it and I will post some pics later

looking good, have any more pics to update your progress?

yeah, I've been kinda lazy and trying to get back into the school grind. The aluminum couldn't ship before I left so I'm gonna have to pay someone to do it out here:(

That's how I make my tubing cuts. It helps to cut some short peices, at different angle's, then just trace around the outside edges, and cut away.

Keep the small angled peices somewhere, they come in very handy when fabbing up tubing.

the PBB chop saw nothing method works well also http://www.pirate4x4.com/forum/showt...=chop+notching

looking sweet though.
Is it mounted to the underside of the frame as well? or just the side and front?

time to build some sliders

Using paper towel rolls as mentioned in the pirate thread is a really good idea!

Can't wait to see it when you get more free time.

Don't forget to make a mount for that spud gun too! :rockin: Nothing like bombing through the desert after jack rabbits with a spud gun on the grill. :D

Erich

HAHA! for sure i'll remember to make a mount for the spud gun. We used a milwaukee portable bandsaw for ALL cuts for my bumper (magic tool). We guesstimated all cuts but using paper towel tubes is a great idea. I'll post more pics in a couple days, I have a $90 piece of aluminum I have to get cut up for the skid plate. I wanted to buy a 2'x2' piece of 1/4" 6061 aluminum. Instead I had to buy a 36"x48" piece because they had that size laying around and they would charge $25 to cut it. It seems to me that if you sell a product by the foot squared you wouldn't charge your customer to cut it.

yeah, sliders are next on the to do list. My rockers are what make me the most nervous when I'm wheelin. I really want to incorporate a hitch reciever for a winch and a hoop for lights but I am lacking a welder right now, and bender, and saw. damn