Re-building/Repairing a TJM Bumper

[4x4mike]

So... I acquired a TJM T-17 bumper that was involved in a little fender bender. I had always wanted a T-17 but when I was looking to buy one they were all gone and there were no more U.S. sales. I cruised online here and there but didn't really want to hassle with it.

When this came along I decided it was time and I figure I'll try to salvage it.

Pros:
It was given to me.
It's not all bad.
Came with new frame mounts and bumper wings.

Cons:
It's bent.
The bent portions are made of thick metal that can't be bent back.


Not my pics but this is the bumper with some notes of the damage.
https://lh6.googleusercontent.com/-lHkIlTrxKKY/UA2DEE0Y-KI/AAAAAAAAwC0/xHHVLR9qbc8/s800/12.JPG

https://lh4.googleusercontent.com/-5-SfdvWp5oY/UA2DEbqVQaI/AAAAAAAAwC8/N0RiANEB4FU/s800/1.JPG

https://lh5.googleusercontent.com/-Y4PFo4SZmsk/UA2DHF8P15I/AAAAAAAAwDU/Z-XKKv660Z4/s800/4.JPG




When I received the bumper some attempt to repair it had been started by means of a cutting torch. The driver side wing had been cut off and the lower portion of that wing had been removed. The remaining, large section, bumper is in ok condition with just a slight bend on the top.

I started with the driver side wing and put it in the vice. I pull here, a tug there with no results. For fear of ripping the work bench off the wall I put it on the ground and went to work with a bottle jack and some pieces of wood, still no luck.

It was time to start cutting. I made some relief cuts in hopes of being able to bend the metal but it's just too thick and the twist actually makes it stiffer. Relief cuts turned into removing material cuts.

[4x4mike]

It's August here, probably the same where you are. August means it's getting warm. The garage is decent to work in and I like a good sweat but the grinder doesn't like the heat and wrestling a hot jagged bumper is not all that fun while dripping sweat.

This weekend is going to be hot.
https://lh4.googleusercontent.com/-WXV7plq0ebo/UCPxah1OkYI/AAAAAAAAwIk/p95u319yMZw/s800/2012-08-09%252010.17.48.jpg

While I'd love to work on the bumper in what free time I have (family and family stuff) I'll be at my sister's house Friday through Sunday building 300 feet of fence :screwy:

Here is what I have done. You can tell where the torch had been taken to it (not me) and see where the grinder was taken to it (me).

https://lh4.googleusercontent.com/-FX8JUTxtGBM/UCPxDcinO5I/AAAAAAAAwH8/M-ObOamq0Hg/s800/IMAG1706.jpg

https://lh3.googleusercontent.com/-VwDpflDARCc/UCPxT0QIhyI/AAAAAAAAwIU/of6xQrlGc18/s800/IMAG1709.jpg

The plan is to use the cut out pieces as templates. The front plate and top plate were one piece that was bent at a 90 degree. As such it's pretty stiff. I decided to leave the bend for a couple of reasons. 1)It ensures I'll have a correct length wing when I'm done, 2)It'll help making sure what I build is straight and in plane, 3)It'll help having fewer pieces to lose or have to clamp/hold on to when melting it all back together.

[4x4mike]

Yesterday I was able to hit the steel supply shop on the way home from work while doing other errands. From what I could find online the TJM and ARB bumpers are made from 3mm thick steel. While the steel yard guys know what 3mm is when you ask them if they have something similar they give you an annoyed look.

Anyways, just thinner than 3mm is 12g and just thicker is 3/16" plate (in stock material). Most everything I've made on the 4runner is out of 12g so I know how to bend, weld and cut it real well. Since this bumper is thicker than 12g and I don't want it breaking I went with the 3/16". This shop has tons of remnant pieces of EVERYTHING but didn't have a ton of 3/16" unless I wanted to buy a 4' X 8' sheet.

I didn't plan the trip too well so I didn't have measurements or my cut out pieces so I was going by memory and wasn't doing too well. He did have a 2' X 4' piece of 3/16" so I decided to buy that instead of making multiple trips because of coming up short. This piece will give me more than enough material for the repairs and a lot to spare. I feel better with the 3/16" than a combination of 3/16" and 12g.

So far, when time permits, the plan is to replace the 2 pieces I cut out. Rebuild the lower section of that wing (the factory piece is beyond repair) and begin to reattach it to the rest of the bumper. Before re-attachment I'll most likely have to mount the good section of the bumper on the 4runner and make sure everything lines up and that I don't weld anything too askew.

Additional plans for the bumper may include integrating my factory Hella micro DE lights into the lower portion. Making a more permanent outlet for my forward OBA hookup, mounting my Cadillac horns as well as adding my HID converted Hella 500ff's. I would love to add a single row LED light bar but right now that's just dreaming. I've got a couple ideas of how to mount it while keeping it safe and secure but they are too costly right now for something that won't get a lot of use.

I'm posting all this to document what I'm doing but also to get some ideas. There is a chance I'll have to replace the curved section of the wing (corner) which will be challenging. I'd hate to cut the entire thing out because getting a new one in there might be tricky without making it crooked. Bending plate to match the curve will also be hard for such a small piece.

[Robinhood4x4]

I hope you mean 1/8" :D

Sounds like a good plan and a good way to keep everything aligned. I like it.

[Seanz0rz]

ditto on the 1/8". 1/8" is closest to 11 gauge, 10 gauge is a bit thicker, 3/16" is closest 9 gauge.

looks like a good plan keeping the factory bend, im looking forward to seeing how it comes out!

[4x4mike]

Whoops, it's 3/16ths. Brain fart. I was trying to get all that down with the pictures during my break and fumbled. The guy said he sometimes had 10g but it had been a while and he probably wouldn't have had enough.

[4x4mike]

We got the fence done in two days instead of one and it was a good thing. Crazy hot, really hard work and I think I've only pee'd 4 times in the past 3 days. Anyways, here is the sheet I bought, makes a good table to work on.

https://lh6.googleusercontent.com/-NVNyyTIuUKU/UChewW7APMI/AAAAAAAAxgM/ZxgBYa5R1Fg/s800/IMAG1734.jpg

Got to cutting and then some more cutting and $7 later.

https://lh4.googleusercontent.com/-0bWBHUE5CUE/UChe5qOda-I/AAAAAAAAxgY/v7kJFm3rrXA/s800/IMAG1735.jpg

I had two pieces cut out. Yes just two little pieces. I've never worked with 3/16" before and it's thick. On top of that it was about 100* in my garage and my grinder was working hard. It got so hot I'd have to put it down. After awhile I pulled a box fan out there and angled it at the grinder. My digital thermometer said the grinder was getting 120* and it was too hot to handle even with leather gloves on.

After a little I decided I was going to go broke buying cutting wheels for the grinder so I turned on the air compressor so I could use the cut off wheel. I've got about 30 cut off discs so I thought, cool. Well, the compressor gets hot even in the winter and with the cut off wheel it wasn't shutting off. Plus it wasn't cutting anywhere as fast as the grinder with a cut off wheel.

I decided to plug the grinder back in a go for broke. This is what I have to show for it.

https://lh4.googleusercontent.com/-6Mqi8yDHrg4/UChfAPAXyeI/AAAAAAAAxgg/Y9sTDYAQKjU/s800/IMAG1736.jpg

https://lh6.googleusercontent.com/-uLSr6hPPR2g/UChfIafoizI/AAAAAAAAxgo/ngiiH2Eixf8/s800/IMAG1737.jpg

Next was a bend in the top piece. I cracked open a beer because I knew if the steel was that hard to cut it would be a bear to bend. I decided to do the ol' score and bend like I did on my skid plate. It worked well but required quite a bit of scoring to get it to bend.

My piece on the left, TJM piece on the right.
https://lh6.googleusercontent.com/-Lgp5oqyKgFo/UChfPJKpUUI/AAAAAAAAxgw/BxqwZDG7PoE/s800/IMAG1738.jpg

Part of what made this hard was that the bent up piece was small. Had it been wider there would have been more to grab onto.
https://lh3.googleusercontent.com/-Tfa-W_jaBxw/UChfkd5lk0I/AAAAAAAAxhA/ErkMHpybknk/s800/IMAG1740.jpg


Both of the pieces I cut out are a little larger than the hole they go in. The reason being is that I really only want to cut these out once. Bummer part is on some sides they are about 3/16" too large and grinding them down is taking forever. I've used the bench grinder and the angle grinder and both don't take off enough material fast enough. I wish I had a plasma cutter :loser:

[Seanz0rz]

mike, the harbor freight cut off wheels are some of the best i've found. they last a decent amount of time, cut well, and are inexpensive. the way i cut stuff like that is to score it and score it, making even passes, and dozens of them. trying to cut through the thickness all at once and walking it up the piece usually takes longer (or so it seems, should be the same, but whatever)

as for taking down that last bit, i always have used flap wheels. dont last as long but really will move material if you ask them to. 36 or 40 grit work great for fitting like that.

good luck!

[4x4mike]

I welded the back side of the bend so it's good and solid. It's been awhile since I've had a welding project and I forgot I have a POS welder. It's the 120v HF flux core and it's not feeding well. Kind of does a bbz-bzz--bzzzzzz-bbz-bzz. As such the arc is screwy and creates booger welds and spatter.

I need to monkey around with it but I don't want to weld the entire bumper back together. I have several other options so I'll probably go another route for when the pieces get finish welded.

I started grinding away at the replacement top piece I cut out and realized I need to know when to stop grinding. I can eye ball stuff but the bent and twisted piece I have isn't the best template. I decided to clamp it to the other side of the bumper and I knew the dimensions of the puzzle piece I was making. I spread it out and twisted it into shape. Now that it's clamped I grind then fit, grind and then fit. So far I have done a lot of grinding and need to do more. Wife and kids came home so I had to pack up everything so that's as far as I got today. I'm sure my neighbors will hate me by the time I'm done making all this racket.

https://lh6.googleusercontent.com/-rvxfoihqSIE/UChfre6cT4I/AAAAAAAAxhQ/IaShHOjXrqg/s800/IMAG1742.jpg

[4x4mike]

mike, the harbor freight cut off wheels are some of the best i've found. they last a decent amount of time, cut well, and are inexpensive. the way i cut stuff like that is to score it and score it, making even passes, and dozens of them. trying to cut through the thickness all at once and walking it up the piece usually takes longer (or so it seems, should be the same, but whatever)

as for taking down that last bit, i always have used flap wheels. dont last as long but really will move material if you ask them to. 36 or 40 grit work great for fitting like that.

good luck!


I like the HF 3" wheels I use for my air powered cut off wheel. Problem was air consumption and the heat though. My compressor wasn't happy and stuff wasn't cutting. On my 4.5" grinder I used a Norton branded cut off wheel and a Diablo which is supposed to be real good. I got two different Diablos and the thicker one seems to last a bit longer.

For scoring I did what you said. I wanted the score to be straight so I started light and made it super straight. I then went back over it again and again. Here and there I'd stop to put it in the vise but every time, more scoring. I think I was pretty close to going through before it bent.

[CJM]

What kinda grinder you got? My makita 7.5amp cuts stuff like that pretty easy

[4x4mike]

I've got a Craftsman Professional, 4.5".

The grinder doesn't bog down and the wheels are cutting it just takes awhile. One of the above pieces uses about 60% off a cutting wheel.

[CJM]

Id think it was the grinder. Ive used craftsman power tools before and wont buy them, they arent built as they once were Mike.

IE: My friends 19.whatever volt impact driver struggles vs a porter cable I got and porter cable is cheaper stuff too. Chances are your angle grinder is not powerful enough as it should cut even with cheaper blades, relatively well.

Id buy a more HD grinder as in the long run its worth it.

[Seanz0rz]

i have probably the same craftsman grinder, and it is one of the best tools i have bought. about 4 years ago i did pull the head apart and replaced the grease with some awesome high temp moly stuff, and that seemed to be an improvement.

wheels make a big difference. The worst wheels I've had were dewalt wheels. they lasted forever, but refused to cut anything. i ended up tossing the wheel with about 75% left because it was unusable. the norton ones ive had are OK, but bang for buck, the harbor freight 4.5" are the best.

also depends on your steel, cold rolled vs. hot rolled, what grade, alloy, etc.

[4x4mike]

My grinder is a 7 amp model that is about 12 years old now. I know they don't make things like the used to and I'm pretty sure it was the wheels. This grinder has a lot of balls and wasn't bogging down. I love this grinder. It's outlasted all the ones I've bought after it.

Sean, I've been meaning to take the head apart and check it. I'm sure after the heating it got it could use some fresh grease. I just saw the forecast and it's unseasonably warm (HOT) for the rest of the week. I'm not sure I'll be working on this much.

https://lh5.googleusercontent.com/-oQ24tlNlny0/UCklp2tknQI/AAAAAAAAxh0/_mUHwM2B9Wg/s640/2012-08-13%252009.04.23.jpg

[Robinhood4x4]

I don't work in that kind of heat in the day and around here it stays in the 90s at night. If it got down to 65 at night, I'd be working at night and in the morning.

[4x4mike]

Funny. It's almost 10pm and it's still 85 which is not the norm. I''ve been super busy anyways so it's not a huge deal since I probably couldn't work on it anyways.

[Bob98SR5]

mike, consider using cardboard and use that as templates if you're not getting the exact measurements you need

[Seanz0rz]

posterboard works great, especially the one with the half inch grid lightly printed on it. i've used that alot!

[4x4mike]

I usually use cardboard but didn't this time because of the bend. I only wanted to cut it once and didn't want to come out short. As it turns out it isn't that far off. Life is really busy with family and kids so I haven't had a lot of time to work on it. I had about 5 minutes tonight and almost got the piece with the bend in it to fit. Another 5 minutes and I'll be there.

[4x4mike]

I got a little time to do some work on the bumper. So far I'm pretty happy with how it's coming out. I'm not too happy with my welder and may be looking for another. Mine is having wire feeding issues and it's causing some sloppy work and trying my nerves. I'll be looking for deals but at the same time continuing on my with my work.

I got both pieces semi welded in. For the most part I'm trying to get the pieces in there. I'll probably have someone else weld from the back side to really burn it in place. Mine is in there but doesn't have the penetration I want or need. This is good though because it will keep this piece from warping which is what I'm fixing in the first place.

I'm really glad I kept that bend on the little wing. It has helped me keep things in alignment and making 2 pieces was easier than one piece with a bend in it.

I've ground down most of the welds as I'm trying to make this look as it hasn't been repaired. Like I said the backside will get burned in some more. There is still some more grinding and welding to do but that will be for later.

When I uploaded the pic I realized I still have a relief cut to weld. It's the small vertical cut on the front.
https://lh6.googleusercontent.com/-JjwJImJ7bts/UDF6Mt92l8I/AAAAAAAAxsY/ggZATKoDCis/s640/IMAG1780.jpg

Front
https://lh6.googleusercontent.com/-jnLUWnxTAco/UDF6Vt2y79I/AAAAAAAAxso/sfPqXW_fmmw/s640/IMAG1782.jpg

Kind of weird angle but it shows the thing is square again. It used to have quite a twist in it.
https://lh3.googleusercontent.com/-w2Alitb5Dgw/UDF6aiuT-fI/AAAAAAAAxsw/zZnmz-t3JSM/s640/IMAG1783.jpg

https://lh3.googleusercontent.com/-opwfLyEs4KI/UDF6rSqgp3I/AAAAAAAAxtI/okXDzpMh74E/s640/IMAG1786.jpg

This is the next piece to build. I think parts will be fun and other parts will be hard and annoying.
https://lh5.googleusercontent.com/-j6okIOWXddo/UDF6wcHuXLI/AAAAAAAAxtQ/CqmUfS9uvgI/s640/IMAG1787.jpg

https://lh4.googleusercontent.com/-sPGjHv-5JJs/UDF68fEdIPI/AAAAAAAAxtk/KQakSkTRZbY/s640/IMAG1789.jpg

Bent, twisted and dented. At least the other side is usable as a template.
https://lh4.googleusercontent.com/-vAHDazXsEDA/UDF7AIveDNI/AAAAAAAAxts/7rZUFehZH_o/s640/IMAG1790.jpg

[Robinhood4x4]

You can always bevel the edges to get better penetration.

[Bob98SR5]

great job mike!

[4x4mike]

Twice I've typed up an update but it times out and then there is nothing. First one was kind of good, I think. Second one had more pictures and was funnier, to me.

Now I give up :thumbsdown:

I worked on the bumper yesterday and it's coming along. TTFN.

[Seanz0rz]

mike, i always write up my longer posts in notepad, copy paste them over, and then save them to my desktop in the event the post gets deleted (it's happened a few times).

[4x4mike]

I know. I usually copy the entire text before posting. This way if it times out I just paste the thing back in and I'm good to go. I did it this last time but failed. I was trying to be funny and was describing what was going on while I was working on the bumper and why I needed to start cleaning up. I typed up everything, copied it and then started to proof read. When I was done I thought one more picture was in order (of my son sacked out and poopy - you had to read the story) so I copied in the link.
Well, when the SOB timed out I pasted in my "text" and all I got was a link to picasa, dang it!
Gave up and got back to work. Work-work.

[4x4mike]

Fine I'll just do pics.

https://lh5.googleusercontent.com/-c_C2ddxVzVc/UDcTvEc5w7I/AAAAAAAAxuQ/kQ5safDPYMk/s800/IMAG1798.jpg

https://lh6.googleusercontent.com/-9e1wP5DCY-o/UDcTyoMYm2I/AAAAAAAAxuY/dtQtFcHXiJ8/s640/IMAG1799.jpg

https://lh6.googleusercontent.com/-W84YWbTQPnY/UDcT3EQ-v2I/AAAAAAAAxug/8D90rSYiozE/s640/IMAG1800.jpg

https://lh3.googleusercontent.com/-Q9ObTjnxDbQ/UDcT8ZmuEbI/AAAAAAAAxuw/UPK3KsmhmtE/s800/IMAG1802.jpg

https://lh5.googleusercontent.com/-HDUtuujBiM0/UDcUArAX8BI/AAAAAAAAxu4/XCu1a1r-H9Y/s800/IMAG1803.jpg

https://lh5.googleusercontent.com/-hDxtZunqrIE/UDcUDeXUQ9I/AAAAAAAAxvE/ibIu64HoK54/s640/IMAG1804.jpg

https://lh5.googleusercontent.com/-m2YmixPv4T8/UDcUJFEFwUI/AAAAAAAAxvU/URhb6ggf5g4/s640/IMAG1806.jpg

https://lh4.googleusercontent.com/-3rheQlsakI0/UDcULg46LTI/AAAAAAAAxvc/gvFFyQ7BSQ0/s800/IMAG1807.jpg

[4x4mike]

i have probably the same craftsman grinder, and it is one of the best tools i have bought.


Yes we do have the same grinder. I agree, it's a very good one.

Yours
https://lh6.googleusercontent.com/-8jpPLOA2U5o/UDfWoVZhw2I/AAAAAAAAxwk/JGz2Vcfex70/s800/Sean%2527s%2520Grinder.jpg

I looked and looked and only found a blurry photo of just the top of mine. I thought I had a better one but it's time to take pictures of the tools again.

[4x4mike]

Little time means little progress. It also means just pictures.

Another handy tool used on the old piece to transfer to the new piece.
https://lh6.googleusercontent.com/-Tj3gAsYf44s/UDqaK5SExhI/AAAAAAAAyCo/5Op5Q6a0wrg/s800/IMAG1812.jpg

https://lh6.googleusercontent.com/-QrmiCf6-huk/UDqaMesCK9I/AAAAAAAAyCw/1LI6oYZlKH4/s800/IMAG1813.jpg

Tacked
https://lh6.googleusercontent.com/-ZXZlepc713w/UDqaQE3PeVI/AAAAAAAAyC4/LBHAuhDY1bM/s640/IMAG1814.jpg

More tacking. I need to make sure everything is where it needs to be. I have a feeling there is still grinding and fitting needed.
https://lh4.googleusercontent.com/-SQfWRjCvIg8/UEBPgoo5DTI/AAAAAAAAyDo/I_9m_O6MxXA/s640/IMAG1830.jpg

[Seanz0rz]

looks good. going to have it installed for Pismo? coming to pismo?

[4x4mike]

Yeah I'll be at Pismo but I'm not sure about the bumper. I'm busy enough that I only have about 30 minutes to work on it every 4 days or so. I also don't want to fully install it until I'm done with everything I want to do to it.

I've got the turn signals I want and have to slightly modify the wiring hence the reason not to take the bumper on and off a bunch especially if I can only work on it here and there. I also need to figure out my fogs and a few other things. This is on top of everything else plus the bumper isn't needed for Pismo so I don't want to rush it.

Who knows though. Maybe one day I'll get some hours on it and it will be done.

[Crinale]

It sucks modifying a DD. You can't leave it in pieces while you work on it!

[4x4mike]

Kind of. It's not so much about the DD as I don't need it for the most part during the week. It's more of a time thing. Work, hobbies, training/racing, friends/family and kids leaves little time for things like modding my DD. I commute on light rail and bicycle everyday so it can sit but I just don't want it sitting too long and in the way. That and when I do need it I don't want to spend the time putting it back together just to take it apart again.

After today I will have commuted 407 miles on my bicycle in the month of August (not bad considering the average temp for the month was 94* - ironically this past January I also commuted 407 miles). Most of the daily driving I do is random BS stuff here and there and can be done with my wife's car if need be.

I've got a lot of vacation time stocked up but if I'm at home I've got kids, quiet nap times and the honey-do list to contend with.

[Bob98SR5]

mike,

amazing work, man. keep it up. whats the name (brand n model #) of that awesome tool?

[Seanz0rz]

bob: http://www.amazon.com/Empire-Level-2754-Contour-Gauge/dp/B0000TFIBW

they are available at home depot and the like.

[4x4mike]

Yep Sean, you found it. I got mine at Home Depot just randomly a long time ago. I'm glad I did because when I need it, it's invaluable.

Today was a busy day but I managed to get some welding and grinding done. I also started cutting down a 40 foot tree in my yard (I hate having nothing to do-this tree is big and dead but is not going to fall or hurt anyone how it stands, total ADD + chainsaw :hillbill:) that is next to high voltage wires, telephone wires and power lines. Mowed the lawn, vacuumed the house (I kind of have to do that after I go tromping through the house after I've been in a tree with a chainsaw), played with the kids, finished laundry and went out to dinner with friends.

I started by finish welding the bottom piece. It went pretty well and was in a groove when I ran out of welding wire. I spent about 30 minutes transferring 1 pound of wire onto a spool from a 10 pound spool :chair:

After I cleaned up that mess I ran extra beads around the other work I had done last week. In some of the places there were just tacks. In others areas extra bead was needed because I was having wire feeding issues when I was working on that part.

No one had come out of the house looking for me so I started to grind. I pretty much used up an entire 4.5" grinding wheel grinding smooth welds and smoothing out the very bottom piece. It looks pretty good but it still a little rough here and there. The plan is to hit the rough parts with Roloc discs before primer and paint.

https://lh4.googleusercontent.com/-q5LwDcEIhK0/UELnk196LpI/AAAAAAAAyE4/ZGC9hw6UIdY/s640/IMAG1844.jpg

All together, solid and straight.
https://lh5.googleusercontent.com/-kHpjNqDHFXk/UELnqCkC0_I/AAAAAAAAyFI/ofIb5Sm3QkI/s640/IMAG1846.jpg

https://lh4.googleusercontent.com/-hh_h2B4lQds/UELoDiR7V5I/AAAAAAAAyFs/gZM0Nx5k0AI/s640/IMAG1850.jpg

[4x4mike]

Still no one came looking for me so I continued. I decided to go with some oval LED turn signals. I looked all over at pretty much every type that was out there. I wanted LED but wasn't sure on the size, shape or emitter. Some are mega bright and others kind of small. I feel like I chose a style that I will be happy with.

They have superflux type emitters and use a bezel for attachment. I was going to go with the rubber grommet but I wanted something a little more solid and secure. I also wanted them to be pretty straight considering I have to cut holes for them. I can do one fine but to make the other side match in location and plane could be a challenge. I figured the bolt/screw in would suit me best.

Light. Apparently the middle 4 can be turned on as a running light and the remaining 6 as the turn signal. I'm not sure how to do that as there is no information regarding wiring configurations. I put 2 of the leads to power and they turn on so I know they work. I'll call the company next week to talk to the tech staff.
https://lh5.googleusercontent.com/-jV7C_Bm1P78/UELoJEEi-YI/AAAAAAAAyF0/2MJ2-2ohpaw/s640/IMAG1851.jpg


The non damaged side of the bumper has a cut out for a rectangle turn signal. The hole is too long so I had to fill it in some. I used a piece of the damaged rectangle cut out from the damaged side and welded it in.

https://lh6.googleusercontent.com/-tNd0zLLa1Ew/UELn2GobUjI/AAAAAAAAyFc/YQEXM6PIULE/s640/IMAG1848.jpg

Here you can see the hole with the scrap welded in. The hole was from the scrap and the old hole was welded in. One other thing I like about the bezel on the lights is that they cover the opening and I don't have to cut an oval hole to hold the light. The screws will hold it in nice and tight.
https://lh4.googleusercontent.com/-YbEoEeJAFS0/UELn7rKHgjI/AAAAAAAAyFk/xVd8RwOtISk/s640/IMAG1849.jpg

I need to do some mock up and some measuring but I'd like to incorporate the factory fogs in the bumper. I need to make sure they fit and will project properly at the higher bumper height.

https://lh6.googleusercontent.com/-lBKQj2rp2G0/UELoQoONljI/AAAAAAAAyF8/KkOn9-E7Ll4/s640/IMAG1852.jpg

[Bob98SR5]

:wrenchin: thanks mike. when i think i dont have enough cool tools.

looking really good, man. cant wait to see it after its all done. somethign tells me it'll be better than original :clap:

[Seanz0rz]

awesome work! I like those lights! The only thing I hate about my oval lights are the grommets. I think it is a stupid way to mount a light. But it does do a pretty good job, and I think it minimizes the vibration transfer.

[4x4mike]

The grommet and loose fit is what I wanted to avoid. The likelyhood of me getting 2 perfect oval holes was slim to none so this affords me some wiggle room.

[Obi..]

Just get it close enough and slot the screw holes if need be. You can't tell me you don't have access to a laser level? *Reminding myself I need to reset my floods.

[4x4mike]

There shouldn't be a need to slot my mounting holes. I just need to ge the big hole in the right place. I can use a laser level to set the lights but finding the same spot on both sides of the bumper might be hard. It appears as if there is still a slight bend on the top. It's all one piece now so things like this are apparent. Now it's tweak and weld time.

[4x4mike]

In order to get a hole in the vicinity of where I needed it I decided to clamp the wing I've been working on, onto the bumper so I could transfer lines. It actually worked really well.

https://lh4.googleusercontent.com/-0B18tyVI1V4/UELogMb1VJI/AAAAAAAAyGQ/5G0ZyL3VKU4/s800/IMAG1854.jpg

It's always nice to have a second set of hands especially working around fumes, sharp edges, sparks and heavy metal objects. This was my helper until Mom came out and lured her away with cookie baking. At least she'll be well rounded.

https://lh3.googleusercontent.com/-RizmSciMGLI/UERIe4Yr0FI/AAAAAAAAyGw/I07kPg9yclQ/s640/IMAG1858.jpg

She helped me cut the hole for the light and gave me a few pointers. She also went inside to get my belt since she said my butt crack was showing, sheesh. I also started to weld in the wing. It was a little high on one side so I cut the welds and ground down the edges. I may have to do it again to drop the far outside edge.
https://lh4.googleusercontent.com/-Bdcn7kv-OHo/UERIwTyyJUI/AAAAAAAAyHA/h-7wU4LAh7k/s800/IMAG1861.jpg

https://lh5.googleusercontent.com/--MIm7uZkDFc/UERI4BOM-0I/AAAAAAAAyHI/Ku5Y6cbmPY0/s800/IMAG1862.jpg

Drilled some holes snapped my fingers and they lit up. They seem to be a nice brightness and I'm wondering if they will be brighter with a running engine and say 14 volts. Hopefully soon I'll be able to answer my own question.

https://lh6.googleusercontent.com/-QQUYwmjrLkM/UERJEHxtkHI/AAAAAAAAyHc/zK2F6imnDEE/s800/IMAG1863.jpg

[Crinale]

Looks like it's coming along quite nicely there! :thumbup:

[Good Times]

lookin good mike!

[4x4mike]

Well I've gotten to the point where I need to mount the bumper to make sure things are where they need to be before they get burned in. I decided to remove the stock bumper and mount the TJM bumper brackets to mount the bumper. I ran into a problem though. The frame ends of 3rd gen 4runners differ (as well as other portions of the frame). The '98 brackets are different than the brackets needed for a '99-'00 frame.

I've got some feelers out and some emails tracking down some brackets. I figure they are available because people wreck these and need replacements, I just have to find where they are hiding. If worse comes to worse I could cut the brackets I have to build up some but right now I'd rather not as I'd probably bugger them up.

Here is what I'm working with. The large flat piece on the front of the frame rail does not exist on a '98. As such the brackets are different.
https://lh6.googleusercontent.com/--Ms8_IcVrRw/UEiqxPQdwAI/AAAAAAAAyKQ/QIu0jLqjRjE/s800/IMAG1885.jpg

This is one of the brackets I have. It's a real nice one but it won't fit around the flat piece on the front of the frame rail.
https://lh6.googleusercontent.com/-OOTiaLkIEiE/UEirT1Si63I/AAAAAAAAyLA/6RGv0Gpftz8/s800/IMAG1891.jpg

These are the brackets I need. I found this picture on the internet and it's obvious it's different than what I have, bracket wise. I spent a good 15 minutes with the brackets I currently have thinking they would work. Mixing left with right, upside down, etc.
https://lh4.googleusercontent.com/-ysc94Crz4j0/UEjaMhfF03I/AAAAAAAAyLs/Pmn3Z2asxMU/s800/bumper3.jpg

Does anyone have any ideas of where to look for some brackets? I'd rather not pay to have them made even though I basically have half the bracket. I've got emails into Steve at Sonoran Steel and Slee.

[Seanz0rz]

On my shrockworks, the end cap gets cut off and the bracket fits around the end of the frame. a new piece with a welded nut gets welded inside the tube to bolt the bracket to the frame head on.

[4x4mike]

Steve Schaefer said he had to cut the frame ends off his frame to mount a TJM on his 4Runner. You have to do the same on ARB bumpers. I'd hate to cut the ends off to find the bumper isn't really going to work or look right.

I'm going to look for some brackets and then take a good look at the brackets I have. One the ones I have the bottom and side holes are where they need to be. I can either trim down the front plate on the frame and/or modify the bracket around the frame plate. I need to crawl under there again to see if this is feasible.

[Seanz0rz]

PM bruce, maybe you can get ahold of him that way. He is the only other 99+ i know of off hand.

[4x4mike]

Good idea. If he bought his bumper for his year it would have come with the correct brackets. This bumper I'm working on had been sitting at his place before I took it over.
I've been told he'll be at Pismo so I'll pick his brain and check out his setup in a few weeks. Maybe I'll bring the brackets I have and compare and maybe make a template.

[Obi..]

Cccccoooommmmmeeeee oooonnnnn, just man up and cut them off Mike. ;) It isn't like you couldn't tack them back on with some side plates if you were to change your mind.

http://2.bp.blogspot.com/-heeJ_jpTS38/TWKrwsrL1SI/AAAAAAAABN4/QUUPU4vwm-o/s1600/you+can+do+it.jpg

[slomatt]

With the ARB you have to perform a bracket-ectomy, I'm assuming you would have to do the same with your rurrent TJM mounting system.

If you do, then it's a good idea to weld in some angle iron to keep the front of the frame from collapsing. In fact I need to do the same thing for my new/used winch, so welding party at your house. :)

- Matt

[4x4mike]

Winch? Good stuff.

The plan is to try to modify the brackets. I'll have to check everything out then try to look at Bruce's setup and go from there. I just need to find time to pull the stock bumper again and sit down and work on it.

Or just wait for some brackets to pop up. I'm waiting for Australia to email back about them. This is part of the response I got from TJM USA: "Because the 4Runner was discontinued after 1995 in Australia, they didn?t produce any T-17s for their domestic market, so chances are that they won?t have anything."

[Bob98SR5]

Good idea. If he bought his bumper for his year it would have come with the correct brackets. This bumper I'm working on had been sitting at his place before I took it over.
I've been told he'll be at Pismo so I'll pick his brain and check out his setup in a few weeks. Maybe I'll bring the brackets I have and compare and maybe make a template.


mike,

i'm pretty sure bruce gave me everything TJM related in his garage, but definitely 2x check with him.

[4x4mike]

Bob, I just want to see his bumper and mounts since he has a '99. Assuming he hasn't bent the heck out of what he has I was hoping to make some measurements.

https://lh5.googleusercontent.com/-GOemWceU-ZM/RxLU99U_bRI/AAAAAAAAiBA/SSvsrX7uhO8/s800/DSC_0148.JPG

https://lh6.googleusercontent.com/-sxV2C_v_Qtk/RxLU_NU_bSI/AAAAAAAAiBA/5uaQW9EeWUk/s800/DSC_0149.JPG


Actually, by the looks of it Bruce and Colin have/had the brackets I need.

https://lh3.googleusercontent.com/-IS7-R3oXJsg/RxLVSdU_beI/AAAAAAAAiBA/h3vv9x1QCLQ/s800/DSC_0164.JPG

https://lh3.googleusercontent.com/-ayPvPCaLRnI/RxLVbdU_blI/AAAAAAAAiBA/dGKtADn17yE/s800/DSC_0184.JPG

[Bob98SR5]

mike, just looking at your pic vs mine on my writeup, it just appears the only difference is your plate vs the rounded nose cone on mine. toyota doesnt make huge changes to accommodate cosmetic changes like a new style bumper. i bet its just that front plate and everything behind it is probably identical to mine.

i would think the best way is to trim that front plate like you said and tap the flat plate, weld in some nuts, or weld in headless bolts. many options.

[4x4mike]

Bob, your frame has a threaded hole inside the nose of the frame. It appears like this is the forward mounting bolt for the bracket. I don't have that hole or mounting point. I don't have measurements of my plate but it's kind of large. If need be I'll trim it here and there if the TJM bracket will fit around it. Right now cutting it off isn't in the plans.

Here is the driver side bracket as it sits. The bottom and side holes line up with holes I have in my frame. The angled piece is in the way of the bracket.
https://lh6.googleusercontent.com/-OOTiaLkIEiE/UEirT1Si63I/AAAAAAAAyLA/6RGv0Gpftz8/s800/IMAG1891.jpg


I'm thinking that if I cut out the angled piece the bracket will fit on the nose. If it does the angled piece of steel to the left of the hashed box looks like the '99 bracket I posted above. Perhaps that is the biggest difference in the brackets.
https://lh5.googleusercontent.com/-Q1-bXuliT4M/UEo19JR67lI/AAAAAAAAyNU/OlaPYC2Dbtw/s800/bracket.jpg

Next I'd weld on (blue box) more metal to the front of the bracket to mate up with my frame plate, drills some holes and put in some bolts. The frame plate already has welded nuts on the backside. The red box is supposed to be the frame.
https://lh5.googleusercontent.com/-nzFskP9u-Yw/UEo19STdQxI/AAAAAAAAyNY/zEs2HrJEcqk/s800/bracket2.jpg

Maybe...

[Bob98SR5]

hmmmm...could be!

[4x4mike]

Well I made some more progress today. Part of that was removing the factory bumper again. After doing some reading about the factory bumper and the TJM the factory bumper is quite heavy. I lifted mine a few times today and can attest. I think it's about 25 pounds lighter than the TJM but still a heavy one.

I sat and stared the factory plates at the end of my frame. They are pretty big and I wanted to cut them but not cut them off. The factory bumper is held on by 12 bolts. I cut the frame plate off along with two threaded nuts so my factory bumper now will only be held on by 8 bolts, I think that's plenty.

Stock
https://lh6.googleusercontent.com/-ifyIx-fE8sU/UE0pVpom8tI/AAAAAAAAyPo/3upZAvhYZkE/s800/IMAG1909.jpg

Other side but same thing, just trimmed.
https://lh5.googleusercontent.com/-YNZmMbhETXM/UE0pbDLbhII/AAAAAAAAyPw/NUwZBu-XI7U/s800/IMAG1910.jpg

So I trimmed the plate and bolted on the TJM frame mounts. The bumper pretty much went right on. There is still some alignment issues and I have to finish weld the bumper but it's looking good.
https://lh5.googleusercontent.com/-AmT8v-82v8A/UE0phdfasgI/AAAAAAAAyP4/hD_BO_tvRbo/s800/IMAG1911.jpg

I'm pretty sure the '98 brackets put the bumper where it needs to be. All the mounting holes are oval so there is a lot of adjustment. Hopefully this week I can get some time to push it around and see if everything is straight enough to look right. Then I'll finish welding, grinding and painting. Until then I'll slap my license plate on and rock this. I'll figure out the turn signals later.

[Bob98SR5]

wow grreat work, mike! cant wait to see it in person

[4x4mike]

The time has come that I need to drive again so the bumper had to be painted and put on. I've gone through 2 cans of primer, and about 5 cans of paint (so far).

The paint was still a little soft so I have some touch up to do but it's on and looks better than half painted. Once it dries and cures I'll be able to align it as well. Right now it only has half the bolts and is cockeyed.

https://lh4.googleusercontent.com/--Rj8KMshKN8/UFKxu9XaXPI/AAAAAAAAydY/pB6LLFf0Fls/s800/IMAG1925.jpg

https://lh4.googleusercontent.com/-gick62F55cI/UFKybTpIjSI/AAAAAAAAyeM/VMvIfmC3cF0/s800/IMAG1932.jpg

https://lh4.googleusercontent.com/-H4DnMdFnAko/UFKyM-oC8KI/AAAAAAAAyd8/o6EgQsdSYNk/s800/IMAG1929.jpg

[Bob98SR5]

cna't wait to see this in person

[Good Times]

lookin good mike! awesome job :thumbup:

[Obi..]

*Put a straight gauge across it. J/K :D LOOKS NICE MAN!

[4x4mike]

It appears I'm done for the time being. Paint needs a little touching up here and there. The whole bumper also needs to be moved towards the drivers side and down. I also need to clean and straighten out my license plate as it looks a little out of place next to new paint.

Before:
https://lh5.googleusercontent.com/-PCPIlc_-7g8/UFdI9KyxpLI/AAAAAAAAygA/FblEHeF1c2g/s800/Presentation1.jpg

After:
https://lh3.googleusercontent.com/-L-SBPdlsM00/UFcncQEyYNI/AAAAAAAAyfA/Vv1jZUV8XDE/s800/IMAG1942.jpg

[Seanz0rz]

looks great!

[Crinale]

Very nice work Mike! How does the front suspension sit now with the extra weight? Although, you did say the stocker was heavy, so is it even effected?

[Good Times]

Dang I feel bad for the chump's 4runner on that before pic ;) hehe

Mike, looking at the before and after pic you did an amazing job getting that thing back together like it came factory! awesome work bud!! :thumbup:

[Bob98SR5]

looks like the driver's side still has a weee slight upwards cant, but damn dude, great job!

[4x4mike]

Very nice work Mike! How does the front suspension sit now with the extra weight? Although, you did say the stocker was heavy, so is it even effected?


I'll have to look up my front measurements and measure again but I don't notice much if any change. The ride is the same as well.



Dang I feel bad for the chump's 4runner on that before pic ;) hehe

:thumbup:


Ha, Ha!



looks like the driver's side still has a weee slight upwards cant, but damn dude, great job!



Yep it's still up. I'm not really sure which piece of the middle section is tweaked but I'm hoping to level it out soon. I think I may alter the mounting holes a bit, crank down one side, tweak it and crank down the other side.

For the most part it looks good from far. Thanks guys.

[Seanz0rz]

I could winch it back into shape for you!

[4x4mike]

Thats an idea. It needs to be pulled down which would be easy to do while in a dune. Biggest problem is that I'm sure it's in the middle section and winching may cause more damage in that section.

[Bob98SR5]

wouldnt the truck sink too while you're winching downward? I think this doesnt sound like a winning strategy

[Ric]

:clap: nice job

[Seanz0rz]

mike, the winching idea was a joke. It never goes very well, ask me how i know!

[4x4mike]

Joking? Oh sure.

I've got the day off and both kids (mommy's work day) so what better time to spend the morning than bench pressing a bumper? I got the rest of the hardware I needed and got to tweaking. The goal was to mount the bumper as level and even as possible. Not messing up the new paint on it would be a plus.

The damage to the bumper was on the driver side and as a result the bumper tends to flare up on that side leaving the passenger side either level or drooping depending on where the mounts were on their oval mounting holes.

I tightened down the driver side about 80% then pushed the passenger side into place and bolted it up. Over all it looks pretty good.

For paint I went with the black hammered paint I use on my sliders and skid plate. It's nice stuff but the bumper is kind of big so it's a lot of paint. It's a bit glossy too so we'll see if I keep it. Flat black is a bit too industrial and has that faded look. I tried a black metallic but it didn't have the look I liked so I put the hammered over it.

To control the fast turn signal blink I replaced the factory flasher with an EP-35 and all is back to normal.

This morning, with the skid plate off due to an oil change.
https://lh3.googleusercontent.com/-twKEFS1ctPQ/UFyzeH_mobI/AAAAAAAAyhI/THpYxl3Fvk8/s800/IMAG1952.jpg

With the Hellas installed.
https://lh3.googleusercontent.com/-HehAS5LA5Tg/UFyzlzYLYCI/AAAAAAAAyhQ/TOJJ_O5yC3U/s800/IMAG1953.jpg

It looks much more level than previous pictures. The Hella lights are also an indicator and they look more level. Now all that's left is to re-install the bezels around the turn signals and I'll be set for awhile...finally.

[Seanz0rz]

:hillbill:










http://i103.photobucket.com/albums/m141/hamiltoncomputers/DSC02166.jpg

[paddlenbike]

Looks great Mike!

[843Tacoma]

The time has come that I need to drive again so the bumper had to be painted and put on. I've gone through 2 cans of primer, and about 5 cans of paint (so far).

The paint was still a little soft so I have some touch up to do but it's on and looks better than half painted. Once it dries and cures I'll be able to align it as well. Right now it only has half the bolts and is cockeyed.

https://lh4.googleusercontent.com/--Rj8KMshKN8/UFKxu9XaXPI/AAAAAAAAydY/pB6LLFf0Fls/s800/IMAG1925.jpg

https://lh4.googleusercontent.com/-gick62F55cI/UFKybTpIjSI/AAAAAAAAyeM/VMvIfmC3cF0/s800/IMAG1932.jpg

https://lh4.googleusercontent.com/-H4DnMdFnAko/UFKyM-oC8KI/AAAAAAAAyd8/o6EgQsdSYNk/s800/IMAG1929.jpg




Not to change the subject but do you have any idea where I can get those side pieces that you have for your bumper? I just bought a TJM for my first gen tacoma but the bumper is missing the side pieces. Just wondering if you knew where I could find them. Badass rig by the way.

[4x4mike]

The side pieces came with the bumper but I'm pretty sure they are generic. Even if TJM made different ones there can't be too many different part numbers. I also say this because mine don't have part numbers on them. In my search for frame mounts I emailed all kinds of dealers and TJM's around the globe. Turns out Slee bought out all the remaining parts from dealers in the US (So they say). They have a lot of parts but they aren't cataloged. Give them a shout and see if they have anything for you.

The bumper made to Pismo and back with zero problems. The improved approach angles actually helped and this was my first trip that I didn't munch my front license plate.

https://lh4.googleusercontent.com/-w2U8boXrox8/UGi0S_sY6qI/AAAAAAAAy4U/AvNYLzS5GVE/s800/DSC_0134.JPG

[Bob98SR5]

843Tacoma,

Seriously, if you have the main piece, you can mock up the wings out of cardboard. There are really no funky angles on those wings. Before I gave the bumper to Mike, I had thoughts of measuring the dimensions of the T17. Yes, its that linear w/ exception of the bottom part of the center section. So raid the local Fedex or UPS of large boxes, blade, ruler, and scissors and make a cardboard mockup template.

[jrallan26]

Great job on the bumper! How are the LEDs working out on the front bumper?

[4x4mike]

They work really well. I have them as running lights and turn signals. Nice and sealed and just the right brightness.

[4x4mike]

With winter here I've been doing a lot of driving in the dark. The factory headlights are only ok so I decided to get the Hella Micro DE's back on the 4Runner some how. The factory bumper had cutouts so the lights lived on the inside of the bumper. I had thought about integrating them into the TJM but there wasn't as much space in the locations I wanted them. Plus the lights would have had to be aimed pretty downward to do the job correctly.

Lights. These have a 3000K HID DDM kit in them.
https://lh5.googleusercontent.com/-iM9c5wEHo0I/UNfYZvYzewI/AAAAAAAA02Q/qL9tzm4vTgk/s640/IMAG2329.jpg

I found a nice little spot on the side of the frame rails where the TJM bumper mount bolts to. I used 2 factory bolts to hold a little mounting perch that I made out of some scrap.

https://lh4.googleusercontent.com/-zgtb54l_c1E/UNfYbsSO_xI/AAAAAAAA02Y/Dv13_fgL4Uw/s640/IMAG2330.jpg

They are just slapped together but hold the light much better than the old set up. I capped the end of the square tube to keep water out but I may also drill and tap the cap to mount my rocklights as they lived where the Hellas do now.

Here you can see a partial install. My 4Runner came with the Micro DE's stock with a switch as part of the turn signal stalk. When I removed the stock bumper I wired the turn signals into the stalk switch and used them as running lights. Here one DE is wired and one turn signal wired. You can see the driver side DE tucked under near the frame.
https://lh4.googleusercontent.com/-gGlYJU_2noU/UNfYd-YN_MI/AAAAAAAA02g/nxuobXegXBY/s640/IMAG2332.jpg

Here they both are.
https://lh4.googleusercontent.com/-XIUp9-aZJHA/UNfYjXEv8YI/AAAAAAAA024/ubYY7CWQ-vA/s640/IMAG2335.jpg

I no longer have my turn signals as running lights but I may pull a wire from the side marker light if I feel the need. The DE's are about a foot inward from where the used to be but you can't tell when driving. These lights, especially with the HID, have a lot of side spill and are much brighter than the stock H3 bulb. I still have some aiming to do but I'm very happy with them and glad I finally found some time to get them back on.

[Bob98SR5]

mike, looks really goood! merry christmas . im up in walnut creek since yesterday fyi

[4x4mike]

Merry Christmas Bob. I see you came to join us for our wet weather. We've been hosting family for the past 4 days so now we're going to try to hit the road and spend some time in the snow.

Thank you and Merry Christmas to you and your family as well.

[paddlenbike]

Looks good! I used the heck out of my HID micro DE's in all of this rainy/foggy mountain driving I did over the holidays.

[4x4mike]

Well it looks like I'll be doing a little more work on the bumper. The repair and work I did on it seem to be holding up just fine but it needs a new coat of paint. I'm also going to be building a box or sort of case for a 20" light bar. My HID retrofitted Hella 500 FF's were stolen off the bumper and for not much more I can get into an LED bar.

https://lh3.googleusercontent.com/-_-Md2B1BZac/VpkSmWnIXDI/AAAAAAABIwk/ai7DI5O1Umg/s800-Ic42/20160114_194944.jpg

I did some research and looked around and found I wanted a single row bar, not too wide and not too narrow. I ended up with a 20" Rough Country bar. It's got 18.5w Cree's and the box says it puts out 8,000 lumens (the website says 7,200 lumens).

https://lh3.googleusercontent.com/-ahjBSJ5ZWiM/VqGlKbrxMGI/AAAAAAABJBM/xu0Cyt9-UxY/s800-Ic42/upload_-1.jpg

https://lh3.googleusercontent.com/-JXZilJBQn7E/VqGlNG-D_YI/AAAAAAABJBM/83pyWZaMSW0/s800-Ic42/upload_-1.jpg

It's nothing too special but it is very nice. It's got two mounting options and has a super robust plug and play wiring kit. I plan to use the wiring I have in place from the Hellas, I just have to build something to put the light in. My 4Runner lives outside so I don't want this stolen. The 500's were actually my second set stolen. I had a pair stolen off my pickup right after I bought the 4runner.

The box thing will be welded in place. I think I'm also going to make a cap or sorts to encase the mounting bolts under the bumper. My HID's were 55w and I think somewhere in the neighborhood of 6000 lumens each. This bar at ~7200-8000 has so much spill it appears so much brighter and much whiter.

This shot is from Pismo. My PIAA headlight bulbs and HID fog lights fill in so much of the foreground. The Hellas have a lot of throw which is good for roads and trails but in a place like Pismo you see a lot of just the beams.
https://lh3.googleusercontent.com/-HhthZrJuNz0/VqGryUcoIeI/AAAAAAABJBg/jR1Flwhcrts/s800-Ic42/12032738_10207726875434424_2836664423036910011_o.j pg

The 20" bar is just a wall of light. It has throw but not like the Hellas or individual lights.
https://lh3.googleusercontent.com/-YQQ_GXuo_wY/VqGlIwhSRZI/AAAAAAABJBM/sCV1K3IkF4E/s800-Ic42/upload_-1.jpg

Installing this is not high on my priority list but I'll be scraping time here and there to fab something up.

[4x4mike]

Finished up my cap. I was too lazy to head to the steel shop so I used 3/16" as I had a large enough sheet with at least two straight edges to work off of. I was hoping to use something thinner just because it's easier to work with but 3/16 is pretty forgiving in terms of grinding flat and bending. One down side of 3/16 is that the thickness makes scoring and bending hard. The score has to be pretty wide otherwise the material folds into itself before 90*. I wanted to score and bend to make the front-top of the cap look as clean as possible (not all wavy and ground down).

Without going into detail on how this is affixed, the light bar and the cap are bolted to the bumper (not each other). To get the bar off you have to remove the cap. Hopefully this is enough work that people will leave it alone and move onto something else, hopefully on another vehicle.

I tired to keep the material in one piece as much as possible to reduce welding and make the left side match the right side. There are angles and what not but most of my measurements were eyeballed. I only had a half baked idea in my head of how this was going to look and work so I figured little things out as I went along.

https://lh3.googleusercontent.com/-jXTQ63_E4Cs/Vq7Vaqlk7KI/AAAAAAABJCM/rWDmEYnVDsA/s800-Ic42/upload_-1.jpg

This is after much cutting, grinding and head scratching. The front-side wings were scored but broke off when I knocked the piece off the bench. This set me back because the light opening went all polygon on me and it was a 5 hand job to get things all lined up and held in place for spot welding. Once spot welded the wings were no longer movable so I had to tack them on three more times before final welding. This was one of the times I wished I was using a thinner steel. Eyeballing angles and fitment was difficult with chubby pieces.
https://lh3.googleusercontent.com/-KV9ErzMIXhI/Vq7Vc1n8e9I/AAAAAAABJCc/okVlzSqJNXM/s800-Ic42/upload_-1.jpg

Then there was the fitting process. This bumper was crashed prior to me getting it and after the rebuild a small twist and bend remained. Nothing like building something super straight and flat only to put it on a twisted base. I used a flap disc and Roloc pads to massage everything into place.
https://lh3.googleusercontent.com/--e229-ZuiUQ/Vq7VfRnyEPI/AAAAAAABJC0/58ln3DuWeeU/s800-Ic42/upload_-1.jpg

Then paint and waiting for night.
https://lh3.googleusercontent.com/-j3qVADhAn6o/Vq7VvgZr4-I/AAAAAAABJD8/bCJI9rf_WOk/s800-Ic42/upload_-1.jpg

https://lh3.googleusercontent.com/-Ky_J7oLk-r0/Vq7Vy15TfzI/AAAAAAABJEM/xDmNMOhbrXY/s800-Ic42/upload_-1.jpg

At 20" long and single row, the light only has one type of optic on the 18.5w emitters. Longer lights and double row have floods on the side and spot in the middle. The emitters are also smaller, 10w, so there is room for such optics. My bar shoots straight forward with a beam that is concentrated yet has a lot of spill, just not super wide. While driving the sides are a bit dark but nothing like it is when you turn off the bar. Overall I'm really happy with how the cap turned out, the size and quality of the bar and the light output.

[paddlenbike]

Clean!

[Kryptoroxx]

Very very clean! Well done. Probably won't be stolen this time around I am guessing.

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[Seanz0rz]

Very nice!!!