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!

 

BE sure to take lots-o-pics.

 

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:

 

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

 

are you using solid edge?


thats a pretty good model

 

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

 

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!

 

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.

 

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

 

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

 

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

 

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.

 

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.

 

Same here my teacher sucked

Looks great I wish I had some of that software it could come in handy

 

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

 

The teacher doesn't matter... ever, it is how you apply yourself

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

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

 

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