list of materials:
3.5"x3.5"x3/16" square tubing 72" long - main beam
2"x2"x3/16" square tubing 96" long - carrier frame
1.5"x1.5"x3/16" angle 72" long - bottom rock rail
24"x26"x3/16" plate - frame mounting brackets
28"x48"x1/8" plate - side plate (didn't have enough 3/16" plate)
32"x12"x16ga plate - top finish plate on sides
9"x9"x3/8" plate - wheel mounting plate
misc drop steel including some 2"x4" triangular gussets and some 3/16" plate & solid bar for other stuff.
also:
slee spindle (received) - $95 + shipping
hitch receiver and safety chain loop (received) - $29 shipped.
later, i'll order the latch (McMaster-Carr) and hold-open pin (Slee)... about $100 for both in stainless steel.
i got all the steel for the bumper and carrier for about $200 - very cheap considering that some i got out of the supply company's scrap bin and they cut me a good deal on everything else. that includes the 3/8" thick plate that i got the shop to cut and punch for the spare mount yesterday. one company that i called w/ my initial list wanted nearly $500 for only about 80% of what i've already purchased.
i have maybe $100 in the consumables like wire and cutting/grinding/sanding wheels.
i have another $200 in the Stainless Steel latch, Stainless Steel hold-open pin, and Slee HD Spindle.
i should have everything here now with the exception of the poly support tabs on the carrier and the hardware to mount them, the hardware to mount the tag frame, and the studs/lugnuts for the spare and hi-lift mounts. all of that will be about $30 or so at most.
i still need to reroute the exhaust, but i'll just reuse the piece that i cut off the end for the reroute. if i need more, i'll just bend some stainless schedule 5 tube here at work and use that.
it looks like about $140 or so for the steel for JUST the bumper and the rest is for the carrier.
in the end, i'll have about $500 in it and about 50 hours of blood, sweat, and tears, and i'll have a custom rear bumper w/ carrier that's painted to match.
similar bumpers:
here's some pics of the carrier hub/spindle and the main beam cut for the receiver and now welded in place and welds ground smooth.
that's a 2.5" square tube for the hitch receiver laying in a 3.5" square tube for the main rail so you can see how beefy the slee spindle/hub actually is.
and here's what is starting to "take shape" - literally...
FYI: i decided to center the tire for several reasons.
1. balance - center the weight like others have suggested. the moment arm isn't terribly longer by having it centered. equally loads the frame, etc.
2. visibility - w/ the spare to the side, i'd have a huge blind spot on a corner. w/ it centered, the blind spot will be directly behind me - which doesn't matter on the road - and then i can see in the corners where it's most important for lane changes.
3. versatility - it gave me options for mounting the hi-lift out back along w/ a tag frame. the design w/ the tire to one side was kinda funky w/ the tag and hi-lift on it.
4. looks - it just looks better by being in the middle
5. mimicking is the most sincere form of flattery. one of the best bumpers out there for any toyota is the slee UZJ-100 bumper. that one is super stout and works. he has the tire centered. no objections from the owner of the UZJ, so i'm sticking w/ what's worked for others.
at this point, the main rail is tapered and welded up. got the 1.5" angle iron on the center of the bottom rail. still have to get the angle on the tapered part, but first, i wanted to check how it looked.
got the OEM bumper, hitch receiver and spare off today. got the main rail up to where it will be and made a mock up of one of the side wings...
main beam is pretty much finished (for the most part) and i got the mounting brackets fabbed up and welded to the bumper. some test-fit pics:
next will be to get the sides cut to length and cut and bend the wings...
progress pics:
:great:
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http://4rnr.net/p1010027.jpg"][/url] http://4rnr.net/p1010030.jpg"]
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http://4rnr.net/p1010032.jpg"][/url] http://4rnr.net/p1010033.jpg"]
[/url] http://4rnr.net/p1010034.jpg"]
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http://4rnr.net/p1010035.jpg"][/url] http://4rnr.net/p1010036.jpg"]
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Departure angle is much improved over the stock bumper w/ receiver hitch. Now that I finished the hard side, I'll build the other to match.
I have about 20 hours in it at this point and should have another 5 or so in the bumper and then another 10 in the carrier. It's not quick, but it's also being cut from stock in my garage and isn't copied from anything, so everything has to come from my head and my drawings and it just takes time.
It sticks out about 1/2 to 3/4" more at the rear and then tapers to just wider than the flares at the wheel well. it's not as wide as it looks, but the width was definitely driven by the carrier.
I'm planning on just turning the exhaust down somewhere between the bumper and the frame rail, and fab up a protection plate for it, but I don't think I want it out the side at this point.
Somebody asked me about the tag bracket via email...
it's a new OEM frame for a 1990/1991 4runner w/ exterior tire carrier...Originally Posted by bamachem
i got it from Phil at http://www.toyotapartsales.com
for the clamp, i'm going w/ a #2 McMaster Carr Pull-Down Latch w/ Safety Catch - catalog page 2396 at http://www.mcmaster.com. I'm getting item number 51335A68 in stainless steel and 2000# of holding power.
50 hours in labor after it's all said and done...
now for the good stuff:
put 2 coats of rustoleum red oxide primer and then two coats of cheapie flat black just to keep it from rusting while i finish it up.
more bumper porn:
i had to make a jig for the carrier frame cause the pipe doesn't run verticle when looking at it from the side. it actually angles outboard slightly away from the body and also triangulates to support the carrier hub plate - that was fun. it was worth it, cause now i have the look i want and didn't compromise on strength. the 2nd gen tag bracket will completely cover that pipe frame, so it won't be visible at all. the hi lift has the base plate, then an upper support that you can't see behind the tire.
[click a pic for the larger version]
here's the almost completed carrier...
ok, here's the hi-lift mounted. that should be about it except for finishing a few things to wrap up underneath before wheeling w/ it...
:
I just couldn't resist...
Come and listen to a story about a man named bamachem
The guy builds a bumper, now thinks the world revolves around him
Then one day he was driving down the road,
his booty fab bumper broke and he dropped his load.
two coolers...
(6) 7# bags of ice...
a fully cleaned and quartered 110# deer, venison, jerky.
Well the first thing you know ol bamachem's having a fit,
Kinfolk said "That bumper ya built ain't worth a..."
Said "Alabameee is the place you ought to be"
So they loaded up the 4Runner and moved back to Bamee.
Roll Tide, that is. No offense, but no volunqueers.
Well now its time to say good bye to bamachem and all his kin,
And he would like to thank you folks fer kindly droppin in
You're all invited back a gain to this locality
To have a heapin helpin of his bs-pitality.
Hillybilly that is. Set a spell, Take your shoes off so you can count above ten.
Y'all come back now, y'hear?.
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