C.B.I. Gen 3 REAR BUMPER Build

[Chaplain]

Getting a rear bumper on the FUNrunner has long been overdue and has become a huge need for my surf safari and prerunning/race-chasing activities down in Baja. There are two major/serious reasons why the need for a real bumper; 1)I need to be able to carry a full size spare and 2)I need to make room for a fuel cell where the OEM spare is. Too many times the FUNrunner has all but made me walk from running out of fuel. For those of you that haven't ventured south of the boarder; gas stations are few and far between, when you do find one there is a good chance it will be closed or out of fuel. Not fun being stranded without gas in Baja at night.

To accomplish this build I turned to Steve Eagan of C.B.I. Fabrication out of Idaho Falls Idaho http://cbioffroadfab.com/. I have seen Steve's work up close on the Lucas Oil Off-Road Racing Series Bully-Dog pace truck that I ride in. He fabricated the bumpers and rear cage for that truck and it has served well bombing through the short-course jumps so I figured his work would be more then sufficent for the FUNrunners duties as a race-chasing prerunner.

We started by tearing off the old tow hitch and bumper. (hitch for sale)
http://c1.ac-images.myspacecdn.com/images02/14/l_57a7316309b2464fadda44ae20de049c.jpg

Then fabrication started on the bracing for the future bumper and swinger.
http://c1.ac-images.myspacecdn.com/images02/31/l_7afbdafb43ba496396e7680d87c6301c.jpg
http://c2.ac-images.myspacecdn.com/images02/57/l_7291017a209242a387014380cbfffcfd.jpg
Progress seemed slow, but I'm sure tomorrow will look more promising.

Our priorities in this build are to fabricate a performance/duty oriented bumper that is lean, high-clearance but still stout enough to carry needed items (spare tire, fuel jug, jack and breaker bar). I told Steve I didn't want some land-anchor that was all for show and not for go.

Stay tuned to see what we come up with as we are currently slaving away in the C.B.I. Shop. Any constructive input is always welcome.

[4x4mike]

Cool. I'll be interested to see what you guys come up with.

[Ric]

sweet, cant wait to see the finished product :thumbup:

[Chaplain]

Not sure if Steve has little elves working for him or what because somewhere between midnight and 6am some progress was made on the bumper. Not sure how that happened.
Notice the inside bracket to add to bumpers support and still allow it to be "bolt-on".
http://c3.ac-images.myspacecdn.com/images02/82/l_d4844e0e860e45f7b9819196f8a5839a.jpg

http://c1.ac-images.myspacecdn.com/images02/49/l_c1fa6788b0c74be48a101aa8b4c5d91c.jpg

Stay tuned; Steve has some unexpected surprise in-store for this build that I'm sure you will love.

[kregg]

I already want one of these. Sign me up!

[Chaplain]

More progress made:
To reinforce the frame, bumper and receiver hitch a cross brace was installed from inside frame rail to rail.
http://c3.ac-images.myspacecdn.com/images02/12/l_ca4d1c79c8a84117bc3236e842f186fe.jpg
http://c3.ac-images.myspacecdn.com/images02/55/l_c0e7aa51757f4091ac96f5989e7c045a.jpg

Things are moving along nicely and sliding the bumper skin on there you can see what direction Steve is moving. I can't wait.
http://c3.ac-images.myspacecdn.com/images02/2/l_f64746542cd740f7940eb689be2de1de.jpg

For an added option a glove-box is added, Steve calls it the "bumper-box." It ate up a lot of time bending the folds but I think it will be awesome storage for a wet muddy tow strap or just security for the hitch receiver pin inside.
http://c2.ac-images.myspacecdn.com/images02/28/l_13896de120764d65852d635a4ba026a1.jpg

Hey, every pastor needs a holy bumper... :lol:
http://c2.ac-images.myspacecdn.com/images02/48/l_489acbf94ad54e10bc05b6fb729c2835.jpg

[xonetruthcrewx]

Things are looking very nice. Cant wait to see the finished product.

[Ric]

That "glove box" idea is SMOKIN HOT :clap: :thumbup: :bowdown: :drink: what else can I say, I like it, lol

[DHC6twinotter]

Nice! I like these bumper build threads. :thumbup:

[Chaplain]

That "glove box" idea is SMOKIN HOT :clap: :thumbup: :bowdown: :drink: what else can I say, I like it, lol


Thanks its welded in with the lid, turned out real clean and flows well with the rest of the bumpers lines. Very cool and clean!
http://c2.ac-images.myspacecdn.com/images02/35/l_d6cbf639d29148bd88507989d5f2bd41.jpg
http://c3.ac-images.myspacecdn.com/images02/107/l_a1b37815d55d44db830bf950c073ad6a.jpg

Now for the fun part, getting the sides and corners put together.
http://c2.ac-images.myspacecdn.com/images02/12/l_ce299a9c9e164626b719176f3f4fdb2d.jpg

[4x4mike]

Very nice. I wish I had the tools and know how for the cuts, bends and dimples. One day...

[AlexJet]

I know Steve work very well. He build my rear for the '05.
"Chaplain", when you'll see Steve, let him know that I'm buying 02 for my wife and need a rear bumper. He should remember me well as we were going through the design numerous times for 4th Gen. In case he will ask what Alex, mentioned to him that I'm from Toronto, Canada and I'm extreamly happy with what he did for me. So if he can make a second right away from your template, this will be wonderfull. I tried emailing him, but no answer so far (he must of been busy). I have to dig his number from my old notes...

As of your build, I like it and looking forward to see the results.

[Rock Slide]

Chaplain, bumper is looking great. Glove box was a neat idea.

Def looking forward to seeing it finished.

[Good Times]

Steve,

that looks like a great project! can't wait to see the finished artwork :)

thanks for sharing!!

[neliconcept]

looks different the mine for sure

Steve makes good stuff!

[Chaplain]

Off the truck ready to be welded up and a jig made so the rest of you can have one toooo. :) :safari:

http://c2.ac-images.myspacecdn.com/images02/23/l_7578a0cb33164ab79a0396058d164895.jpg

[Chaplain]

Off the truck ready to be welded up and a jig made so the rest of you can have one toooo. :) :safari:

http://c2.ac-images.myspacecdn.com/images02/23/l_7578a0cb33164ab79a0396058d164895.jpg

[Chaplain]

Getting close just need to get the tire swing built, painted and installed. Steve's craftsmanship and welds are so good it was hard to cover it up with paint.
http://c3.ac-images.myspacecdn.com/images02/68/l_d4de6a0dcc864113896ee8e3a7d74892.jpg

[kregg]

Any sort of rundown on a price yet? Looks amazing!

[Rock Slide]

Wow am I jealous! Looks great thus far. :drool:

[Chaplain]

DONE, Whohoooo!!

Bumper turned out awesome and I'm VERY pleased with the shops quality craftsmanship; they have a lot of pride in the products they are putting out there. Many many many thanks to the crew at CBI for their countless hours spent pounding this bumper out and making a jig for everyone else to have one. It was an honor to GET to work along side in the CBI shop, special thanks for all the patients you had with a preacher cutting, welding, and grinding. I learned a bunch and still have all my fingers.:D:D

This bumper is designed to be "bolt-on", outside of drilling a couple extra 9/16" holes and asking the neighbor for some lifting help it fit perfect.
http://c2.ac-images.myspacecdn.com/images02/16/l_75ce7294c3b84976866d743e4aaad52d.jpg
http://c3.ac-images.myspacecdn.com/images02/17/l_64fbd629afda47318194725d8fe0840a.jpg

Show & shine:
http://c4.ac-images.myspacecdn.com/images02/101/l_70dcb32587e045bf99f68ddf88ced83b.jpg

Dimple dies to give it a little race flavor and of course add to the structure rigidity.
http://c1.ac-images.myspacecdn.com/images02/53/l_8ef2aec8c2794b478d86748cc072cefc.jpg

Steve can lay down a nice bead that's for sure. I saved a few of them before he ground them off smooth. I guess some people like the seamless smooth look, but not I when the beads look this good(picture doesn't show well).
http://c2.ac-images.myspacecdn.com/images02/1/l_c20e4b7e62244845a40c472c44e7d79d.jpg

Just the right amount of space. I like how the shop caps the ends to give the bumper a factory/finished appearance and strength.
http://c3.ac-images.myspacecdn.com/images02/84/l_6ff0ad08c2184526a70894373eab21b2.jpg

Form follows function. This is a stout bumper.
http://c4.ac-images.myspacecdn.com/images02/32/l_4a8f19b1dff84bf19d303aab9da9ac6f.jpg


I'll take some pictures of the tire rack when I get it on, but for now I'm off to Farmington NM for WERock's rockcrawling finals.

[Blownmtr]

Ok, wait a minute here... Just stop! that bumper you got there was 500 bucks give or take a few built from CBI? either or that's a pimpin bumper, and far superior looking than the one Sonoran steel fab makes. i have been on a long quest to either find a decent bumper to buy or just build one myself. i do have a fab shop and all the tools required, but that bumper is sick, and well worth the money it seems.

[Chaplain]

Ok, wait a minute here... Just stop! that bumper you got there was 500 bucks give or take a few built from CBI? either or that's a pimpin bumper, and far superior looking than the one Sonoran steel fab makes. i have been on a long quest to either find a decent bumper to buy or just build one myself. i do have a fab shop and all the tools required, but that bumper is sick, and well worth the money it seems.


Yes Sir, this one is from CBI. Your right nobody is producing anything anything to be proud of. I think the CBI boys hit this one out of the park from a form follows function point of view.

If you think this is cool just wait until you see the swinger. It is going to have a lot of desert prerunner/chase influences on it. Stuff nobody is doing!

[Chaplain]

Ok, wait a minute here... Just stop! that bumper you got there was 500 bucks give or take a few built from CBI? either or that's a pimpin bumper, and far superior looking than the one Sonoran steel fab makes. i have been on a long quest to either find a decent bumper to buy or just build one myself. i do have a fab shop and all the tools required, but that bumper is sick, and well worth the money it seems.


Yes Sir, this one is from CBI. Your right nobody is producing anything anything to be proud of. I think the CBI boys hit this one out of the park from a form follows function point of view.

If you think this is cool just wait until you see the swinger. It has a lot of desert prerunner/chase influences on it, stuff nobody is doing!

QUESTION: Since you have a fab shop and are familiar with the cost of steel, what do you think just the material cost of this bumper is?

[Rock Slide]

Show & shine:
http://c4.ac-images.myspacecdn.com/images02/101/l_70dcb32587e045bf99f68ddf88ced83b.jpg


Steve, bumper looks good! I'm diggin' it even w/o the swingout tire carrier.

Couple questions - Is that an exit pipe for your exhaust in the photo above? Not a bad idea...just would take me some time to get used to seeing it like that. Also, by installing this bumper, is the stock spare location void now?

Last question - you mind taking a few more photos of the bumper before the tire carrier goes on? I appreciate your close up shots, but I'd also like to see a few photos from a little further back to see how well the bumper flows with the overall look of your 4Runner. (Would help give me an idea how it'd look on mine.)

[Blownmtr]

Ok, wait a minute here... Just stop! that bumper you got there was 500 bucks give or take a few built from CBI? either or that's a pimpin bumper, and far superior looking than the one Sonoran steel fab makes. i have been on a long quest to either find a decent bumper to buy or just build one myself. i do have a fab shop and all the tools required, but that bumper is sick, and well worth the money it seems.


Yes Sir, this one is from CBI. Your right nobody is producing anything anything to be proud of. I think the CBI boys hit this one out of the park from a form follows function point of view.

If you think this is cool just wait until you see the swinger. It has a lot of desert prerunner/chase influences on it, stuff nobody is doing!

QUESTION: Since you have a fab shop and are familiar with the cost of steel, what do you think just the material cost of this bumper is?

Yes, Great bumper, i love it, and would love to have one myself. As more material cost (for me to build following X pattern) was a 3x3x1/4 square tube, $130 a stick, so 8 feet, 3/16 plate, receiver tubing, other things here and there. probably close to 200, but you never know. Gas bottle might run out, 40 bucks... Could be anything. Plus to be honest, I'm a good welder and fabricator, but not that good. definitely worthy of getting powder coated.

Also i like the idea of the swinger as well, but wouldn't work out for me because i work out of my truck, I'm a mobile boat mechanic so toolbox and all sit in the truck, rear hatch gets opened a lot

[Blownmtr]

Oh and one more things, what's the wait time for the bumper minus the swinger?

[Bob98SR5]

absolutely amazing work. nice touch on the exhaust outlet. yes, post pics from a distance!

[Chaplain]

Show & shine:
http://c4.ac-images.myspacecdn.com/images02/101/l_70dcb32587e045bf99f68ddf88ced83b.jpg


Steve, bumper looks good! I'm diggin' it even w/o the swingout tire carrier.
Couple questions - Is that an exit pipe for your exhaust in the photo above? Not a bad idea...just would take me some time to get used to seeing it like that. Also, by installing this bumper, is the stock spare location void now?
Last question - you mind taking a few more photos of the bumper before the tire carrier goes on? I appreciate your close up shots, but I'd also like to see a few photos from a little further back to see how well the bumper flows with the overall look of your 4Runner. (Would help give me an idea how it'd look on mine.)

I'll get more pics when I get a chance (traveling at the moment).
My exhaust goes up and over the frame rail and out the bumper (to increase ground clearance) that is why we had to cut a hole in the bumper. Steve was really excited about this part (sarcasm). The exhaust outlet had us scratching our heads some because there just isn't a good place to put a 5" hole. The piping is 3" throughout the entire exhaust, outlet/tip is 4" and requires a 5" hole. I either needed to scrap my sweet polished 4" tip or start cutting. At the end of the day we decided on the outlet you see because it has the same lines as the rear fender flares and front fender flares.
I haven't had the exhaust tip reinstalled yet so it will look better once this is done.
old bumper with hole.
http://c3.ac-images.myspacecdn.com/images01/110/l_6c5ac82c4d4bf6bc6d1f181783ad1f6e.jpg

[Rock Slide]

What about the stock spare location...is that now unusable w/ the bumper installed?

[Chaplain]

What about the stock spare location...is that now unusable w/ the bumper installed?
Well it doesn't fit a 33" but it didn't before either, that is why I needed a bumper and tire carrier made. If you are planning on carrying a spare in the factory location then you should tell CBI that when you place an order so they can make any changes to accommodate your spare.

[Chaplain]

Just got this from C.B.I.: They use 3/16" and 1/4". 1/4" for all the mounting and structure and then 3/16" for all the skinning and aesthetics. The recovery points use 3/4" and all of the tubing is .120" wall except the spindle which is 1.5" solid and the spindle hub that is .250" wall.

The price will indeed be in the $600.00 to $700.00 range, just for the bumper, the swing-away is $350.00. So all together it is $950.00 to $1050.00. CBI is trying to keep it under $1k for it all. The next one will tell them where the price is depending on how long it takes to build (1 to 1.5 days). Give them a call and tell them you want the Chaplain bumper. :great:

[Ric]

:clap: WOOW thats a great price, for something that looks awesome, and VERY strong...

[Rock Slide]

Agreed. That's def a good price.

Steve, thanks for the info on the spare tire. I plan to step up to 33s eventually, but would prefer to carry it underneath if possible...I don't really want the swing out tire carrier. But then again, I know a 33" tire is quite large and probably wouldn't fit underneath anyway. Guess I'll cross that road when the time comes.

[Seanz0rz]

just FYI, a 33" tire will not fit under the truck normally. guys have mounted it with out much air in the tire, but what is the point of a flat spare tire?

great looking bumper! ive already started thinking about a way to utilize the space where the spare used to go on mine, and i think including a glove box like item is a step in the right direction! very nice!

[slosurfer]

just FYI, a 33" tire will not fit under the truck normally. guys have mounted it with out much air in the tire, but what is the point of a flat spare tire?


Most flats on our rigs occur offroad, so it's already at trail pressure. Also, I think most people who run a flat spare, have means to air it up if need be. :)

[Crinale]

chris here being one of them... ur 33x10.5 tire is at what, 9psi? but chris has co2 ;)

[Seanz0rz]

personally, if im changing a tire. i rather not have to air it up too.

[4x4mike]

personally, if im changing a tire. i rather not have to air it up too.


You need a faster compressor then:-P I know what you mean though.

[slosurfer]

personally, if im changing a tire. i rather not have to air it up too.


I know what you mean, but .......

Considering that most the people who run a bigger tire and a removeable swing away tire gate/hitch attachment, etc... have a tendency to run with no spare while on the road and DDing their rig, because they can be a PITA to deal with if you need to use your rear hatch a lot. They don't have to worry about airing up or airing down their tire, just about how they are going to get it out to their vehicle. :laugh: :flipoff:

Like I said, mine's at trail pressure (I actually would have to air it down a little to get it to sand pressure), and I generally have a means of airing it up if I need it on the road. Also, it's no big deal to drive slow to a gas station and air up for free if need be, the tire's not completely flat, just aired down. (I mean, I was already inconvenienced by a flat tire anyways, right? :laugh: )

[Rock Slide]

Steve, any new photos you'd care to share? :hillbill:

[Chaplain]

I'll get some more pics up when I get the swinger on. Sorry I've put on a good 4000 miles on the runner this month and haven't had a chance to do much.

[Chaplain]

Finally got the tire swing-away painted, wired, and installed.

Here it is unloaded:
http://c4.ac-images.myspacecdn.com/images02/10/l_83d6dac220334fe88ee9cab1780c39bb.jpg

Detail items installed:
Liences plate light so your not pulled over.
http://c3.ac-images.myspacecdn.com/images02/59/l_a183861df118485e80908fa014849eda.jpg

Double sheer hindge will help support the weight and make it last.
http://c3.ac-images.myspacecdn.com/images02/62/l_56464d1414224d72861cd352e1a71c7a.jpg

Form follows function with the locking handle. You know how all the other guys complain about their swing-away rattleing or the failing, this one wont. I plan to run a bike lock trought the holes of handle and swing-away for increase security.
http://c3.ac-images.myspacecdn.com/images02/53/l_392b7f9b438e492c875cc3a03cf33e92.jpg

Backside unloaded.
http://c2.ac-images.myspacecdn.com/images02/64/l_1e32962e260e4926b4216e99efb14575.jpg

Backside loaded; now you know what all those tabs are for (shovel, breaker bar, floor jack and handle). Remember you saw it from CBI first.
http://c4.ac-images.myspacecdn.com/images02/37/l_82d174588c0e4dc6a04301b9e49d706b.jpg

Next stop: chasing/prerunning baja 1000.
http://c4.ac-images.myspacecdn.com/images02/42/l_e8acc3bde9434585a3073745bc308137.jpg

[Whitey]

Pics aren't working, my good man.

[DHC6twinotter]

wow...very cool bumper! :thumbup:

[AlexJet]

That's an amazing looking bumper. Kind of remind me what I have on my 4th Gen, and soon will have on 3rd Gen as well. Just love it....

[NakSuKow]

Can you take a side view picture? How close is the bumper to you lower corners of your rear hatch? Craftmanship looks top notch.

[Crinale]

thats a very nice bumper... i need something like that for my 2nd gen...

[AlexJet]

First Production Bumper was finished this morning and went to powdercoating.
I'm hoping to get it before Christmas.
Side Note: I have #1 Production Bumper on my 4th Gen (2005) and now having #1 Production on 3rd Gen (2001). Sounds quiet nice.

[97kurt]

What about the stock spare location...is that now unusable w/ the bumper installed?
Well it doesn't fit a 33" but it didn't before either, that is why I needed a bumper and tire carrier made. If you are planning on carrying a spare in the factory location then you should tell CBI that when you place an order so they can make any changes to accommodate your spare.


It is possible to fit a 33 in the stock spare location. I do it all the time when I dont have the tire carrier on. The trick is that not all 33's will fit. My 285/75/16 Nitto terra grappler will rub the panhard if I put it back there. But a slightly used 285/75/16 BFG that I got for $10 from samco fabrications parts bin clears with a 1/4" to spare.

http://imgur.com/AxP3g.jpg

[Chaplain]

Here are a couple shots of the CBI tire carrier loaded up for work chasing the Baja 1000.

http://c4.ac-images.myspacecdn.com/images02/126/l_a7d8e37bf7374352ad2243f0672b430b.jpg

http://c2.ac-images.myspacecdn.com/images02/122/l_32a26fbc228343feb788aac1222e6a2d.jpg

http://c3.ac-images.myspacecdn.com/images02/144/l_353c1c8dbe58428496922e87a598c1c2.jpg

I got lazy and added a quick pin to hold the gate open.
http://c1.ac-images.myspacecdn.com/images02/152/l_e0f4f470f69e40fcbd8c957dade0cd7c.jpg

[AlexJet]

As I can see production design h as been slightly changed in small details.
I have 1st production unit sitting in my garage since this afternoon. I hope I'd be able to find time to put it on this holiday season...

[neliconcept]

you just reminded me to call Steve about my gas can holder he hasnt sent me yet, been over a year lol

[AlexJet]

Good News.
Ver.2 Bumper was dropped off last night. Installation scheduled for this Saturday, may be we'll start Friday afternoon if everything else will go smooth.
Pictures to follow.

[AlexJet]

Version 2 was tested and figment was much better. This means this is GO AHEAD. Several issues with pre '99 and post '99 trucks were addressed. Now the bumper fits both easily.

Here are some installation pictures.

Rear bumper removed:

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation1.jpg

New one ready to go in:

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation2.jpg

Additional holes were drilled in the frame:

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation3.jpg

And ... its done:

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation4.jpg

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation5.jpg

http://i96.photobucket.com/albums/l183/Aviator_1/2001%204Runner/Bumpers/Installation6.jpg

There are a few minor issues needs to be addressed, but basically it's DONE.

[Rock Slide]

Looks great Alex. It turned out real nice.

I'm jealous.