Rear bumper fab... A few questions... [Archive]

kregg

10-29-2009, 08:28 PM

Well, i've begun the cardboard mock up process of fabbing my rear bumper thank to my mom's new vaccum cleaner box...

I have a source for 3/16" plate steel, my only question: If I were to make the side wings out of the 3/16", instead of the 11ga. as suggested, would ya'll forsee any problems/issues???

I know the weight would be a factor, but is there really that much of a difference?

Thanks for the help ya'll!!!!

Chris

Seanz0rz

10-29-2009, 08:37 PM

well, it will be aprox. 50% heavier than the 11 gauge.

it also depends on your offroading style. if you like using your armor to move you about, to guide you (such as a tight turn on your kick out on your slider) or if you want it to adsorb impact.

for me its both. i rather it fold than the frame or body. however, i sometimes use it to keep my body off a rock, so it needs to be sturdy for high stress and low impact situations. im not done bracing everything on my bumper like i want it to, some of that will come later, and some much later.

Lee

10-30-2009, 09:12 AM

it wont be an issue.

my 3rd gen 4runner's bumper was entirely 3/16ths, with the frame mount being a tow hitch cut and flipped.

http://kidmoe.com/4runner2/tirecarrier/1.jpg

http://kidmoe.com/4runner2/tirecarrier/2.jpg

was it heavy? yeah. Too heavy? No.

It was really strong, held up great! Just make sure you run supports from the frame.

kregg

10-30-2009, 10:02 AM

Lee: that bumper is amazing. What rear lift were you running? I have the LC coils right now and am sitting pretty high in the back. I'd like to keep a little rake, but a leveler stance would be nice too...

Lee

11-12-2009, 11:07 AM

i was running ome coils in the back

kregg

11-13-2009, 08:45 AM

So... What about building the bumper to match a 2" body lift? Yea or Nea?

Robinhood4x4

11-13-2009, 09:08 AM

Sure, why not?

kregg

11-13-2009, 09:42 AM

It'll be frame mounted, unlike the stock rear bumper... Would there be any forsee-able issues?

YotaFun

11-13-2009, 09:55 AM

It'll be frame mounted, unlike the stock rear bumper... Would there be any forsee-able issues?

Frame flex in the rear, guys usually do a little gusseting around the arch over the axle for a little added strength back there, at least from most of the writ-ups i have see...

Lee

11-13-2009, 10:17 AM

keep in mind, you want some space between a steel bumper and your body panels. if you hit something particularly hard it WILL flex (you want it to, else your frame will do the flexing which can tire it / bend it out of place).

i left a good 2 inches as you can see and even that was kinda close.

if you dont like the look, you can get some garage door weatherstripping from home depot or the like and 3m tape it along the edge. this will give it a nice clean look.

also, i would add a new crossmember across your frame near the mounts.

so if your frame looks like this

________

________

add an xmember by the rear mounts

________
|
__|_____

oh and that xmember can just be 1x1. just something to help it out.

kregg

11-13-2009, 10:58 AM

Crinale

11-13-2009, 11:22 AM

The LC coils will handle a bumper just fine... if anything it might level you out a little, but i doubt much... i have the rear LC coils on my 2nd gen, and towing a 6000 lb trailer didnt droop the LC coils all the way down... so an extra 100-150 lbs on the back is nothing...

Seanz0rz

11-13-2009, 02:08 PM

I've definatley considered bracing/plating the rear potion of the frame... Hadn't thought about a new X-member though... Would you recommend keeping the stock one, with the spare tire winch? Or cut that one out and just go with a new one all together? Anyone running the LC rear set-up have any problems with the coils being too soft to run a rear bumper / carrier?

i cant comment on the LC coils too much with a rear bumper, i have airbags in the rear. but before that i noticed the coils were pretty soft, when fully loaded i was reverse raked or exactly level. id recommend the air bags regardless. i put them in knowing i would be towing a trailer with a tire carrier on the rear bumper, plus a vehicle full of stuff.

Crinale

11-13-2009, 05:05 PM

technically you could sean... just drop ur bags to 0 psi and see what it looks like...

CJM

11-13-2009, 05:15 PM

^ shouldnt ever let airbags get that low when on a vehicle-can cause them to blow.

Seanz0rz

11-15-2009, 08:26 AM

yeah, airlift has a VERY good warranty, but you cant get the bags lower than 5psi. when im offroad i dump the air but thats a different story.

im still working on my tire carrier today, but ill dump the air out and see how it sits with a mostly loaded rear bumper (mind you mine is 3/16" and 1/8", so significantly lighter than what you are proposing)

Lee

11-21-2009, 04:23 AM

I've definatley considered bracing/plating the rear potion of the frame... Hadn't thought about a new X-member though... Would you recommend keeping the stock one, with the spare tire winch? Or cut that one out and just go with a new one all together? Anyone running the LC rear set-up have any problems with the coils being too soft to run a rear bumper / carrier?
keep the stock one in place...

I added a small one at almost the very back of the frame. With no spare there, I had plenty of space to put one. Wish I had pics of it :(

kregg

12-19-2009, 07:07 AM

Well I've got my rear bumper designed and mocked up in cardboard... I've already cut the ends off of the center beam and am witing fo things to slow down enough at the shop so they can cut the pieces for the sides... Still not entirely sure how I want to mount it... Any more suggestions?? Thanks ya'll!

Seanz0rz

12-19-2009, 05:31 PM

i would personally use bruce's design again with a plate on the top. same mounting system i used (i still have to make a plate, maybe next week)

the other alternative is to capture the frame like this:

____
| |
| |
| |
|___|

before the body mount (to the rear of it)

and like this ahead of the body mount

___
|
|
|
___|

so the bumper would slip inbetween the frame rails, supported by the hitch bolts on the bottom of the frame and resting tightly on the top of the frame. i hope that makes some sense. those diagrams are for the left side frame rail looking at the back of the vehicle.

BruceTS

12-25-2009, 11:22 PM

a few teasers on how I'm making my side wings now.......

http://img19.imagevenue.com/loc84/th_36297_D08158_122_84lo.jpg (http://img19.imagevenue.com/img.php?image=36297_D08158_122_84lo.jpg) http://img209.imagevenue.com/loc567/th_36300_D08159_122_567lo.jpg (http://img209.imagevenue.com/img.php?image=36300_D08159_122_567lo.jpg)

Using a plasma torch to cut out the pieces and now making the 3 bends in my press brake after I made a few mods to it. Where before I had to weld the top plate....

kregg

01-13-2010, 10:47 AM

Well, I've gotten all my peices cut... Mine will be more of a weld together type deal because I don't have access to anything that I can use to make bends in 3/16th" plate... They are riding around with me in the Runner until I can get to a welder... Baby steps...

BruceTS

01-13-2010, 07:35 PM

my welding is slowly getting better.... :hillbill:
http://img183.imagevenue.com/loc445/th_36303_D08181_122_445lo.jpg (http://img183.imagevenue.com/img.php?image=36303_D08181_122_445lo.jpg)

I recently hotrodded my little 110v welder and it runs some really nice beads now.

http://img268.imagevenue.com/loc16/th_36306_D08193_122_16lo.jpg (http://img268.imagevenue.com/img.php?image=36306_D08193_122_16lo.jpg)

4x4mike

01-13-2010, 08:46 PM

my welding is slowly getting better....

http://img143.imagevenue.com/loc185/th_39569_D08181_122_185lo.jpg

I recently hotrodded my little 110v welder and it runs some really nice beads now.

http://img45.imagevenue.com/loc769/th_39735_D08193_122_769lo.jpg

Not too hijack too much but how did you hotrod your 110v welder?

BruceTS

01-14-2010, 04:13 PM

Well, I've gotten all my peices cut... Mine will be more of a weld together type deal because I don't have access to anything that I can use to make bends in 3/16th" plate...

I used to use a 4 1/2" grinder to cut a groove halfway through the plate, then it made it easy to bend, afterwards you simply fill it with weld. Much easier than trying to line up the plates and holding everything in place.

As for my 110v welder it is simply used as a backup, got a millermatic 200 or a miller 180SD TIG to do most of the work now. Most 110v welder are stripped of components to keep cost down. Basically there's a transformer to lower the voltage, then a bridge rectifier to change from AC to DC. Problem is the AC has a pause when the cycle switches, hence 60Hz. Higher end welders have a bank of capacitors to keep the DC voltage constant. So I added a cap to my welder, plus a few other changes.

Obi..

01-14-2010, 06:40 PM

Bruce, I'm too exhausted to squint at those pics, get us some high res ones, and of course a napkin to wipe the drool off of the keyboards? ;) NICE!!

DHC6twinotter

01-14-2010, 06:57 PM

x2....bigger pictures please. :angel:

Obi..

01-14-2010, 10:01 PM

So the ideas been seconded, anyone for a third? ;)
http://mypetjawa.mu.nu/archives/MOAR.jpg
http://pix.motivatedphotos.com/2008/7/4/633507895159070146-moar.jpg

BruceTS

01-14-2010, 10:25 PM

OK OK added links just click pictures......

kregg

02-01-2010, 09:13 AM

Bruce, what are the measurements on the new style sides? This "piece together" deal I'm trying is not gonna work... I'm gonna pick up some 1/8th and try the score and bend method... I have to get this done soon, I'm tired of ridin' around with a nekkid rearend!

Scuba

02-01-2010, 12:26 PM

Bruce, how exactly did you "hotrod" your 110 welder?
Cost? Difficulty?

Seanz0rz

02-01-2010, 04:07 PM

Bruce had a thread about it. Search in the tools section is my guess. Hard to look for u while I'm on a iPhone

Scuba

02-01-2010, 08:13 PM

Searched, couldn't find it :(

BruceTS

02-01-2010, 08:25 PM

hehe didn't post it on this forum, but it's in a thread on a welding site.

Scuba

02-01-2010, 08:34 PM

Aww come on hook a brother up with a link

BruceTS

02-01-2010, 08:45 PM

http://weldingweb.com/showthread.php?t=33848

Scuba

02-01-2010, 08:53 PM

Lol I just read 2 pages into that thread, google helped me find it. So uhmm I have some reading to do when I get home, don't feel like reading it all while on the iPhone

BruceTS

02-06-2010, 05:33 PM

Lol I just read 2 pages into that thread, google helped me find it. So uhmm I have some reading to do when I get home, don't feel like reading it all while on the iPhone

If you don't have any knowledge of electronics and how circuits work, don't even bother trying to do the modifications. It was easy for me to understand what they were talking about and making the mods to my welder.

With that said back to the topic at hand. kregg asked if I could fabricate the side wings for him.

Here's the side wings that I will be shipping
http://img249.imagevenue.com/loc227/th_05102_D08213_122_227lo.jpg (http://img249.imagevenue.com/img.php?image=05102_D08213_122_227lo.jpg)

the frame plates for a 1" body lift that are almost ready for install. Still need to cut out top plates and weld them to the sleeves that are bolted on.
http://img201.imagevenue.com/loc448/th_05108_D08214_122_448lo.jpg (http://img201.imagevenue.com/img.php?image=05108_D08214_122_448lo.jpg)

http://img135.imagevenue.com/loc233/th_05114_D08215_122_233lo.jpg (http://img135.imagevenue.com/img.php?image=05114_D08215_122_233lo.jpg)

The other side welded in and ready for shaping. kregg did you want theses plates added as well?
http://img135.imagevenue.com/loc383/th_05126_D08218_122_383lo.jpg (http://img135.imagevenue.com/img.php?image=05126_D08218_122_383lo.jpg)

6" filler piece welded in, it helps with the fitting of the factory plastic top plate. I usually lay the shrould in place scribe a line then trim to fit. Just added this for kregg, for when he gets around to this step.
http://img216.imagevenue.com/loc13/th_05137_D08220_122_13lo.jpg (http://img216.imagevenue.com/img.php?image=05137_D08220_122_13lo.jpg)

kregg

02-06-2010, 06:49 PM

Side wings w/ other plate welded up... I'm super pumped to get this finished... Thank you Bruce!

BruceTS

02-13-2010, 05:15 PM

This is a bumper I'll be installing tomorrow
http://img254.imagevenue.com/loc428/th_08040_D08226_122_428lo.jpg (http://img254.imagevenue.com/img.php?image=08040_D08226_122_428lo.jpg)http://img264.imagevenue.com/loc180/th_08050_D08230_122_180lo.jpg (http://img264.imagevenue.com/img.php?image=08050_D08230_122_180lo.jpg)http://img237.imagevenue.com/loc517/th_08059_D08231_122_517lo.jpg (http://img237.imagevenue.com/img.php?image=08059_D08231_122_517lo.jpg)http://img22.imagevenue.com/loc467/th_08069_D08233_122_467lo.jpg (http://img22.imagevenue.com/img.php?image=08069_D08233_122_467lo.jpg)

Here are the frame mounts with the top plates completed
http://img245.imagevenue.com/loc241/th_08076_D08236_122_241lo.jpg (http://img245.imagevenue.com/img.php?image=08076_D08236_122_241lo.jpg)http://img22.imagevenue.com/loc500/th_08080_D08237_122_500lo.jpg (http://img22.imagevenue.com/img.php?image=08080_D08237_122_500lo.jpg)http://img239.imagevenue.com/loc92/th_08085_D08238_122_92lo.jpg (http://img239.imagevenue.com/img.php?image=08085_D08238_122_92lo.jpg)

hopefully this helps when you install the wings I sent ya....

YotaFun

02-13-2010, 05:21 PM

Bruce, Pics not showing up for me

BruceTS

02-13-2010, 05:26 PM

Bruce, Pics not showing up for me

Try again, was having issues with them loading properly, took me like 10 edits to get them to work

Erich_870

02-14-2010, 06:11 PM

Bruce, Pics not showing up for me

Try again, was having issues with them loading properly, took me like 10 edits to get them to work

Since we're talking about your pics, everytime I click on one there is a pop up that shows some sort of fake American Red Cross add that actually leads to some porn site! YIKES! I'm using google chrome btw.

Erich

YotaFun

02-14-2010, 06:13 PM

Bruce, Pics not showing up for me

Try again, was having issues with them loading properly, took me like 10 edits to get them to work

All good :thumbup:

BruceTS

02-14-2010, 06:44 PM

YotaFun

02-14-2010, 06:51 PM

I have been using photobucket, but webshots is good to I hear

Lee

02-15-2010, 02:05 PM

webshots SUCKS

if you dont care about having an account/gallery, tinypic.com works well.

CJM

02-15-2010, 03:32 PM

I like tiny pic, works very good and is easy to use.

kregg

02-18-2010, 10:16 AM

I got the sides in yesterday... Awesome fab work Bruce! Can't wait to break out the welder! Thanks again!!!

BruceTS

02-18-2010, 07:16 PM

I got the sides in yesterday... Awesome fab work Bruce! Can't wait to break out the welder! Thanks again!!!
Your welcome, if you got any questions on assembly don't hesitate to ask, I'll monitor this thread till you get your bumper done...

kregg

02-19-2010, 10:31 AM

So... The easiest way to add a tire carrier to a Bruce bumper would be... I tink I remember see a bolt on version somewhere... Gentlemen, feed me ideas, I'm at work and bored... Sticky note drawings aren't really helping me picture it...

Seanz0rz

02-19-2010, 03:25 PM

joyce had a bolt on that utilized the recovery points.

BruceTS

03-04-2010, 09:33 PM

There's a picture of my current tire carrier on my cardomain site http://www.cardomain.com/ride/765340/14

kregg

03-06-2010, 10:09 PM

I'll get some better one's later.. Tired tonight...
:ban:

kregg

03-08-2010, 07:33 AM

315/75/R16 Goodyear Wrangler DuraTrac on 16x8 Procomp 8069 Series

2" RB body lift and BruceTS inspired rear bumper

Sliders go on this weekend and the ARB will be re-fitted to match the BL

After that rear cargo system goes in, and re-gear soon after... No new pics really, after I get the ARB fitted I'll take some good ones...

http://i256.photobucket.com/albums/hh184/bama4runner/03072010249.jpg

BruceTS

03-09-2010, 08:37 AM

looking good, hard to see the back view... what was the width of the 2x4 after cutting the angle? I see a bit of a gap where the plastic top plate matches up at. I usually leave a 1/2" vertical gap between the body line and top bumper plate, but you should be fine.

kregg

03-09-2010, 12:53 PM

I'm not sure of the final measurements but I do have a little gap with the plastic trim... I'm working on something to hide it a little. And I completely failed to remember the gap between the bumper and body.. It's fairly snug, I just hope I don't bash it too hard. :chair:

Thanks again for the help Bruce, your workmanship is top notch and is evident in the pieces you fabricated for me!

kregg

03-12-2010, 08:34 AM

http://i256.photobucket.com/albums/hh184/bama4runner/misc269.jpg
http://i256.photobucket.com/albums/hh184/bama4runner/misc270.jpg
http://i256.photobucket.com/albums/hh184/bama4runner/misc272.jpg
http://i256.photobucket.com/albums/hh184/bama4runner/misc277.jpg

Lee

03-12-2010, 01:59 PM

Looks great man.

I'd add a little space between it and the body to allow it to flex when it gets hit, otherwise it'll flex up and crinkle the rear qp, or worse, the tailgate.

If you don't like the look of the gap, you can always add something like garage door weatherstripping from home depot to it. it adheres well and actually makes for a nice visual touch.

Edit: This felt a little like deja vu, and I guess I gave this same advice earlier on page one too :laugh: