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Brucker
11-11-2013, 01:14 PM
With the shop being busy as usual, we haven’t posted a build thread in a while. Thought it might be about time to change that. I have been looking for a clean, unmodified first generation 4runner to replace the little blue shop truck. After a long search I purchased this 1985 4Runner off another member of this forum. It was fairly clean, only some minor rust damage in the rear fenders, had low miles (125K), but had an engine in it that had dropped its timing chain. Since it needed the work, the price was right, so I jumped on it.

Here are a few photos of it as I originally found it:

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash2/36549_631275820216141_2044598172_n.jpg?lvh=1

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc1/994837_631275890216134_2139025063_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/988251_631276016882788_834956081_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash2/164200_631275800216143_2032435643_n.jpg?lvh=1

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1070087_631275943549462_516084410_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash2/995722_631275693549487_1798867273_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn1/1010357_631276090216114_1181378602_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash2/65230_631276106882779_1184062453_n.jpg?lvh=1

Brucker
11-11-2013, 01:15 PM
The 4Runner must be in decent condition as it started attracting a lot of attention. People were stopping in to inquire about it. One of those people is a very good friend and client. He was able to convince me that he needed/wanted it more than I did, and made me an offer I couldn’t refuse. Then we sat down and figured out a build plan for it based on his budget. He has some pretty lofty (read expensive) goals, so the plan includes a couple different phases that can be completed as funds become available.

Phase 1: Making it road worthy

With the timing chain being broken in the motor, and not knowing the details of the rest of the internals of the motor, we made the decision to pull the motor and replace it with a good running, low mileage motor we had taking up space in the shop. Got the old one out and the new one installed and running in under 4 hours, and even with having to swap engine wiring harnesses around, it was a new shop record for me. But in my haste, I didn’t take many photos. The next morning I was able to run it down to our local Air Care Colorado emissions testing center and got it to pass emissions flawlessly.

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1454585_690073494336373_96839642_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/1461065_690073514336371_1446317964_n.jpg

Brucker
11-11-2013, 03:36 PM
Phase 2: Lift, lockers, gearing, armor, and more

With the 4Runner finally running well, we are able to move forward with build. 4Runners offer quite a bit for those looking for a fairly capable rig right from the factory. And some would argue that the 1985 model year would be the most capable of them all as it offered not only fuel injection, a boxed frame, and the normal Toyota ruggedness, but also a highly desirable solid front axle.

Our client’s wish list for this phase includes lift enough to handle 35” tires, with the slight possibility of going to 37” tires at some point. The 4Runner would still need to be able to drive down the road and handle like it did from the factory, if not better. It needed the stock “push/pull” steering upgraded to crossover. He wanted selectable lockers with appropriate gearing front and rear. Wanted custom armor all around, to include both bumpers, sliders, and a simple cage tied to the frame for the front passengers. We took these desires and total budget into consideration when putting together the components list.

We decided to go with Trail Gear’s Classic 4” lift for the front and rear. They offer a fairly complete kit that includes things like IFS steering box mount, shock hoops, axle armor and truss, and complete crossover Hi-steering, as well as new, wider and longer leaf springs all around and all new hangers, shackles, shocks, stainless brake lines, and most hardware needed. Then we would install ARB air lockers front and rear with 5.29 gearing to help move and give traction to the new larger tires.. To all this we would add an IFS steering box, a set of 35” Dick Cepek tires on new FJ wheels, Spidertrax 1.5” wheel spacers all ‘round to finish out the suspension components.

We would then be fabricating a custom plate style front bumper, a custom set of sliders, and a 4 point cage that will be tied into the frame with bushings. And we will be finishing off the armor with a slightly modified rear Trail Gear bumper. And of course we can’t forget to mention that our client wanted us to take care of any and all rust. And he also wanted some custom bedliner work for the interior and lower sections of the body.

Received the first shipment of goods from Trail Gear, lift kits and bumper:

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1459270_690073441003045_656040057_n.jpg

And then the second shipment from them, new loaded 3rd members, arrived shortly after:

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/p206x206/1468779_690073417669714_933039685_n.jpg

With parts finally arriving, we made some room in the shop and brought the 4Runner back in and got it off the ground onto some stands

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1392061_690073771003012_1630814050_n.jpg


Just noticed my new favorite accessory of this fine rig. An original Denver Broncos logo sticker on the rear window:

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1425658_690073891003000_254587933_n.jpg

Squishy!
11-11-2013, 05:44 PM
Cool build. I'm super jealous and really missing my SA rig. :bawl: How much did that trail gear kit retail for?

mikeyhcrana
11-11-2013, 09:45 PM
I love it. It's just like mine.

What are your plans for transmission & transfer case?

Brucker
11-12-2013, 04:53 PM
Cool build. I'm super jealous and really missing my SA rig. :bawl: How much did that trail gear kit retail for?

From Trail Gear website(http://www.trail-gear.com/pickup-and-4runner-suspension): Front kit - $1,153.95 Rear - $786.45

I love it. It's just like mine.

What are your plans for transmission & transfer case?

The plans include keeping the stock automatic transmission and using the block off plate/adapter plate from Inchworm to put dual mini truck t-cases behind it.

Brucker
11-12-2013, 06:21 PM
Tear down begins

We first removed the fabulously 80’s wheels and tires.

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/1385673_690074127669643_1660934467_n.jpg

Then started removing the original spare tire assembly. The factory chain hoist that holds the spare is still in perfect working order. Amazing, since these are usually locked up, and/or destroyed by rust. Gotta love an original Colorado Car!

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1451428_690074194336303_455383854_n.jpg

Then removed the rear drive shaft and shocks:

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/548481_690074274336295_1641225331_n.jpg

Out came the rear axle. Amazing how small these rear's were. Surprising strong for their size as well.

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/1426326_690074351002954_208880536_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1395791_690074367669619_99374623_n.jpg

Then we put the rear in full hover mode by removing the rear springs:

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1470186_690074461002943_606843443_n.jpg

And the rear bumper gets removed:

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1390550_690074657669590_442404276_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/1422581_690074671002922_1173094118_n.jpg

The take-off's pile is getting large already:

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1425520_690074707669585_812940138_n.jpg

Brucker
11-15-2013, 12:04 AM
Having most of the major components removed from the rear, we begin tear down on the front. First things first, we removed the air box to gain better access to the steering box.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1459088_690074874336235_374092835_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/994065_690074794336243_1524532529_n.jpg

Then the front bumper:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1471873_690074987669557_239873260_n.jpg

Try to remove the pitman arm from the box:

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/1463097_690074564336266_1526634509_n.jpg

And since the arm won't budge even with penetrating fluid, we decide to cut the dragink. Then we remove the anti sway bar from the frame.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1394223_690075031002886_1750893323_n.jpg

Removed the box from the frame:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1379635_690075131002876_135455353_n.jpg

Out comes the front drive shaft:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1456674_690075234336199_643132088_n.jpg

And the anti sway bar and shocks:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1455918_690075257669530_2087340635_n.jpg

Then removed the front axle assembly:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1425662_690075351002854_1945437655_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1441504_690075291002860_1515239555_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1464016_690075271002862_1237460236_n.jpg

Brucker
11-15-2013, 12:19 AM
Front spring hangers need to be removed, so they get cut off with the springs still attached. Then the shackles are unbolted from the frame.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1385952_690075511002838_1949879380_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1466191_690075527669503_358777244_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1468578_690075581002831_1384820478_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1003946_690075637669492_1274611700_n.jpg

Then we smooth out the the areas of the frame where the front hangers were. Before:

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc3/1395404_690079477669108_138785002_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/574678_690079564335766_205526206_n.jpg

After:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1425660_690079994335723_72162979_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/482419_690079601002429_1315941454_n.jpg

Brucker
11-15-2013, 12:34 AM
Front axle heads outside to be pressure washed. For as clean as this ride is, the drive train has been completely filthy. The engine was horrible, but the axles are worse. Really need a good bath.

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/994655_690075804336142_1275720653_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1451469_690075954336127_1918496626_n.jpg

You can easily see the grime that was rinsed off:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1456705_690076007669455_2000658879_n.jpg

Axle drying in the sun:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1394180_690076024336120_797978336_n.jpg

Then I forklift the axle back in a set it on a rolling work bench:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1459905_690076047669451_1985388275_n.jpg

and get it set up and stands:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1426195_690076627669393_2027561034_n.jpg

And bring it back into the middle of the shop where we will begin it's tear down

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/p206x206/1394083_690076191002770_2037876901_n.jpg

Brucker
11-16-2013, 11:51 PM
Draining the fluid

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1422532_690076244336098_231789563_n.jpg

Removing the calipers

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1395860_690076291002760_1066905260_n.jpg

Hubs removed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1394437_690076517669404_160091933_n.jpg

Driver side hub will need to be replaced as it is missing some vital parts, like the springs...

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1422606_690077034336019_1587045598_n.jpg

Removed the retaining nuts and washer

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1455129_690076647669391_1702171120_n.jpg

Rotors, hubs and wheel bearings removed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1235442_690076687669387_1225346545_n.jpg

Backing plate removed

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1470355_690076724336050_1467965888_n.jpg

Spindles removed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1466085_690076801002709_1256110405_n.jpg

Axle shafts and birfs removed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1461864_690076877669368_1523302425_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/547860_690076924336030_1594338159_n.jpg

Brucker
11-16-2013, 11:52 PM
3rd member removed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1465262_690077244335998_1575575197_n.jpg

removed the stock tie rod

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1426184_690077477669308_266369557_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1456789_690077551002634_1461160866_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1463079_690077571002632_2106670533_n.jpg

Then cut off the steering stabilizer, sway bar mounts, and traction bar mount

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/969228_690077637669292_1427093226_n.jpg

And cleaned up the axle housing for the new weld on components:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1014005_690077847669271_635177782_n.jpg

Painted the backside of the new components

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/999404_690077371002652_311375237_n.jpg

And tack welded the new components in place

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1451450_690077904335932_97628822_n.jpg

Something that is not included in the kit are steering stop reinforcements. And most will tell you they are a must with larger tires and from the abuses shown through wheeling. So we quickly made up some and tacked the into place

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1394259_690077981002591_293546824_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1426551_690078034335919_1476203563_n.jpg

Brucker
11-16-2013, 11:52 PM
With the new weld on components tacked into place, we aligned our axle jig into the housing and commenced welding everything together.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1395317_690078097669246_587196104_n.jpg

Spring spacer

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/994970_690078127669243_1981903380_n.jpg

steering stop reinforcements

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1471130_690078241002565_1661925207_n.jpg

diff protection

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1395266_690078207669235_1437371548_n.jpg

truss

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1466237_690078397669216_1346286308_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1460012_690078307669225_1386180913_n.jpg

All cleaned up

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1002628_690078367669219_519690700_n.jpg

Hulk
11-18-2013, 11:06 PM
Wow! This is awesome!

nakman
11-18-2013, 11:23 PM
Incredible. But why did the front spring hangers have to come off? perhaps that will be revealed later... Really impressive, will be sweet to see come together!

J Kimmel
11-19-2013, 08:06 AM
I can't speak for Aaron, but factory hangers are thin and weak. When I put one tons under mine (long before linking it) I did the same thing. Aftermarket hangers are WAY beefier and up to the task of bigger tires, etc

simps80
11-19-2013, 12:49 PM
sweet tech thread!

Brucker
11-20-2013, 12:42 AM
Wow! This is awesome!

sweet tech thread!

Incredible. But why did the front spring hangers have to come off? perhaps that will be revealed later... Really impressive, will be sweet to see come together!

Thanks for the kind words. And Jeremy hit the nail on the head when it comes to the factory hangers.

Brucker
11-20-2013, 12:42 AM
Time to install the hi-steer arms. As they came:

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/1382275_690078624335860_595631303_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1425522_690078647669191_551322987_n.jpg

Removed the factory arms along with the shims and studs.

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1459969_690078667669189_1562273402_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/539729_690078734335849_678742116_n.jpg

No need to go with upgraded studs as long as the stock ones are in good condition and are properly torqued along with applying a chemical thread locker.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1459873_690078684335854_844786332_n.jpg

Studs installed with thread locker

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1424359_690078711002518_144154315_n.jpg

Hi-steer arms installed

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1394250_690078807669175_1616343338_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1459924_690078841002505_1027586343_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-frc1/1012476_690078867669169_70519697_n.jpg

Brucker
11-20-2013, 12:43 AM
New loaded 3rd member from Trail gear. I will let the photos speak for themselves:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1450279_690079107669145_1195983344_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1458691_690079021002487_2012081056_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1468812_690079561002433_2076210263_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc1/1454864_690078941002495_129446351_n.jpg

3rd member installed and sealed:

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1424399_690079121002477_658451277_n.jpg

Prepping axle for paint:

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1460019_690079247669131_468001204_n.jpg

And the axle freshly back out of the paint booth:

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/1000266_690079384335784_1947614245_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/561996_690079407669115_874738472_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1451515_690079334335789_915386765_n.jpg

And not liking the way one knuckle moved, we double checked our preload set by shims using a scale. Facotry manual states it should be set at 15lbs of resistance but we are happy with the 14.5 lbs we have:

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/1424357_690079801002409_1531817086_n.jpg

rover67
11-20-2013, 09:14 AM
no new knuckle bearings?

Caribou Sandstorm
11-20-2013, 12:46 PM
Nice thread and garage shop!

Brucker
11-20-2013, 11:14 PM
no new knuckle bearings?

Nice catch and good question! It's funny, I remembered to make mention that I thought I over shimmed a knuckle as it felt too tight and even highlighted rechecking them but never made mention of installing new the hardware. So the downside to updating the thread, is that the only time I have to do so is late at night and in doing so, I sometimes make mistakes and skip over parts of the build. I can assure you that all new trunnion bearings and shims were used. We will be installing new bearings, seals, etc, all the way around.

Brucker
11-21-2013, 11:18 PM
Installed new seals and then both side axle shafts and birfs with plenty of grease. Always a messy job.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1461098_690082617668794_2134239167_n.jpg

Then assembled everything in reverse order from above, including a hub from off our spare parts shelf to replace the broken unit.

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1471858_690082994335423_1787123340_n.jpg

You should notice we did not do an upgrade to the IFS vented rotors at this time to save a little cash. It will get done during a future routine brake job. Axle ready to put back under the rig:

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1470358_690083204335402_347078467_n.jpg

Changing gears a little, we take a look at the Trail Gear front spring hanger. It is about 1.5 to 2 times thicker than the factory hangers making it super beefy for this application:

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1456712_690079647669091_1458523333_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1459744_690079727669083_1848545489_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/1470238_690079747669081_1537804961_n.jpg

With the frame having already been prepped, we are able to make a few measurements and clamp the assembly into position:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1441500_690079897669066_287167268_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1469901_690080317669024_877807248_n.jpg

And weld it into place:

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/993459_690080281002361_2089878029_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1453531_690080327669023_88949044_n.jpg

Brucker
11-21-2013, 11:42 PM
Next up per Trail Gear is welding the bump stops to the spring plates.

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1450785_690080444335678_1481018229_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1396015_690080524335670_1083018509_n.jpg

Now we can move onto the IFS steering box conversion. As it looks before we start, with the stock steering box already removed.

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1451428_690080584335664_644416100_n.jpg

Removed the rubber filler piece:

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1394276_690080614335661_574564619_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1469963_690080637668992_1768394062_n.jpg

Trail Gear's IFS steering mount kit:

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/1452179_690080937668962_328627329_n.jpg

Plates clamped into place as far forward on the frame as possible:

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/1469761_690080967668959_990713332_n.jpg

To create some working room, we unbolt the radiator from its supports but still leave it connected entirely to the motor so we won't lose any fluids. Then we gentle lift it out of our way using a strap and an engine host:

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1457581_690081191002270_206395570_n.jpg

With the holes marked, we drill through the frame and weld the round tubes into the frame and smooth it all out:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1450269_690081511002238_1092602225_n.jpg

Install the new steering box mount plates securely to the frame. Then test fit the IFS steering box to make sure the pitman arm clears.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1464053_690081574335565_1533330122_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1451334_690081684335554_1909111520_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1471997_690081841002205_1265264965_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1012476_690081894335533_229284421_n.jpg

Brucker
11-21-2013, 11:43 PM
Everything clears so it is time to weld up the assembly:

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/1454736_690082201002169_881567991_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1450204_690082227668833_1193333544_n.jpg

And added gussets to each side of the frame just behind the new spring hanger assembly:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1391803_690082271002162_517990852_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1452077_690082314335491_59145152_n.jpg

Once all the welds had cooled we returned the radiator to it normal mounting position. We will hold off on installing the box again as we will still need to install shook hoops.

imhighlander
11-22-2013, 11:52 AM
Such a great thread!! One of the best I've found. Keep it up.

Brucker
11-25-2013, 11:23 PM
Such a great thread!! One of the best I've found. Keep it up.

Thanks for the kind words

Brucker
11-25-2013, 11:23 PM
Time to install the new front suspension. Here is a look at the front components we will be focusing on. Notice the spring plates the we already welded the bump stops onto have been already coated.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1458580_690083337668722_1622184523_n.jpg

The new shackles include all new bushings and grease-able hardware. Some are not huge fans of the grease-able bolts as they are inherently weaker than a solid bolt. But our experience has shown that they are more than strong enough in this application. And that people are more likely to maintain (grease) their bushings when it is so easy for them to do so.

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1471883_690083391002050_1969484189_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn1/1395312_690084754335247_1210448149_n.jpg

We bolt the new springs into place:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1394044_690083411002048_2000436802_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/1469908_690083441002045_1688385339_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1450760_690083471002042_1157634250_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash3/563721_690083521002037_202834458_n.jpg

And then we are able to hang the front axle from the new springs.

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc3/1470369_690083551002034_474831878_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/1459929_690083641002025_691934799_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1458431_690083711002018_1467313311_n.jpg

Installed the wheel/tire combo the client has chosen to go with. FJ Crusier wheels with 35" Dick Cepek mud terrains. First look at it sitting on the 35's

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/1426527_690083881002001_1342407774_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash4/1441183_690083921001997_1921996312_n.jpg

We still need to install wheels spacers on the front axle, but they haven't arrived yet.

Brucker
12-02-2013, 01:57 AM
We start off tackling the rear by a little more disassembling. We remove the stock gas tank skid:

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn1/545967_690084041001985_964163135_n.jpg

Then remove the fuel tank after marking each side of all the lines with different colored tape to assure perfect reassembly. May seem a tad unnecessary but this is done so there will be no confusion later.

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1468648_690084174335305_1113814531_n.jpg

We now focus our attention to the removal of the stock spring and shackle hangers.

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1460234_690084194335303_143800101_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/1459337_690084234335299_1841577435_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/379669_690084251001964_1387513240_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1391963_690084271001962_1870197093_n.jpg

The new Trail Gear hangers as the arrived:

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1463126_690084004335322_1495964614_n.jpg

We lay out the new mounting positions for each spring hanger as per TG's instructions and tack weld them into place. TG offers two different mounting locations for the shackle hangers. One for the pickup (lighter applications) and one for the 4Runners (heavier applications). But based on our experience with these kits we chose to ignore both recommendations and located them to our own specifications. This will lead to a better shackle angle and take care of the "rear sag" problems most 4Runners have when all is said and done.

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc1/1000243_690084474335275_558082116_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/1455877_690084491001940_2096948079_n.jpg

We will fully weld everything at a later date after some test fitting.

Brucker
12-04-2013, 12:58 AM
On to the rear axle. This one goes a lot quicker than the front. But we also won't be finishing it up completely right now. We will be stripping it down and then just tack welding the new spring perches until we can get in under the vehicle to set the correct pinion angle. We start by setting the axle up on stands which are on top of one of our rolling work surfaces.

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1441510_690084061001983_2141689387_n.jpg

Then remove the brake lines

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/559413_690084081001981_1126602615_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/1459758_690084117668644_1946085271_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/1450130_690084097668646_989795797_n.jpg

And drained the diff fluid

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1393733_690084151001974_1202914744_n.jpg

Checking the factory pinon angle so we can get a better guesstimate on where to preset the new perches

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1466116_690084284335294_1881668292_n.jpg

Then removed the factory perches with a plasma cutter

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1456520_690084301001959_1559091218_n.jpg

And cleaned up the housing in preparation for the new perches

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1472092_690084321001957_1277665082_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1454975_690084354335287_75057960_n.jpg

A look at the new perches. Much beefier than stock, and feature 3 different mounting locations for the center pin of the springs

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/1466309_690084337668622_871068990_n.jpg

Tack welding the new perches into place

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1395194_690084577668598_13382611_n.jpg

https://scontent-a-pao.xx.fbcdn.net/hphotos-frc3/1383251_690084624335260_980023979_n.jpg

Brucker
12-04-2013, 02:37 AM
Shifting our focus onto the rear suspension, but mainly just on these components:

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn1/528239_690084694335253_524289812_n.jpg

We have already coated the spring plates and you will notice the hardware is the same as the front.

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1441563_690084731001916_1495266923_n.jpg

Somewhere along the way of this 4Runner's life, she got an aftermarket exhaust system. The rear hanger for it will interfere with the new shackle hanger location. So we removed the exhaust hanger until we can determine how it needs to be modified.

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash4/1471305_690084711001918_92489698_n.jpg

We then installed the new springs and shackles

https://scontent-a-pao.xx.fbcdn.net/hphotos-ash3/1394370_690084787668577_1880169681_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-prn2/1393625_690084844335238_1814837072_n.jpg

And hang the rear axle

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1453538_690084891001900_1818749385_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-frc3/1426202_690084917668564_1181222557_n.jpg

We mounted the other two tires and wheels and were able to let it support it's own weight once again.

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn2/1467428_690084994335223_888912588_n.jpg

https://scontent-b-pao.xx.fbcdn.net/hphotos-ash3/1395201_690085017668554_98236813_n.jpg

We still need to check/set the pinion angle and then we can pull it all apart to finish building the rear axle and fully weld the new hangers. But we are happy with the new stance.

https://scontent-a-pao.xx.fbcdn.net/hphotos-prn1/1392748_690085057668550_1450834429_n.jpg

nakman
12-04-2013, 09:59 AM
Sweet! slight correction I believe those are FZJ80 rims, not FJ Cruiser rims. But who cares, nice work man. :bowdown:

Brucker
12-04-2013, 03:10 PM
Sweet! slight correction I believe those are FZJ80 rims, not FJ Cruiser rims. But who cares, nice work man. :bowdown:

Thank you for the kind words. :beer:

The rims may be originally off an 80, though I pulled them off a stock FJ Cruiser. Guess I just assumed they were OEM for that year. Thanks for the heads up.

rover67
12-04-2013, 03:20 PM
Lookin' good!! I dig the step by step!

Brucker
12-04-2013, 03:37 PM
Lookin' good!! I dig the step by step!

Thanks. Got a LONG way to go before I get this one out of the shop though. And the owner just added on another couple of things he wants done this time around. He is very happy with the way things are coming together, which makes me happy. And the next couple of steps of this build are the more enjoyable ones for me. The custom fabrication stuff, where I get to be creative. Good times!

simps80
12-04-2013, 03:57 PM
the step by step is awesome.

Brucker
12-05-2013, 11:46 PM
Missed highlighting this one with the front axle. Installed the tie rod into the hi-steer arms. Left the drag link out until we install the steering box. I will let the photos do the explaining

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1455158_690086031001786_612397383_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1001432_690086054335117_1440840737_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1457581_690086087668447_1304753074_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1422509_690086114335111_112628796_n.jpg

Brucker
12-05-2013, 11:57 PM
Time to install the rear bumper. We chose to go with the Trail Gear rear bumper as it was priced low but still offered plenty of protection. The owner would like to have something custom made to replace it on a later date, so we will be leaving it alone (no modifications), except for coating it in paint.

Here is a look at the bumper freshly unpacked from shipping

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1471246_690085374335185_238579456_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1450269_690085477668508_850052203_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1461735_690085511001838_500082272_n.jpg

A look at the rear without any bumper

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1471840_690085557668500_91884511_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1395799_690085594335163_1939211308_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1470013_690085631001826_1877319273_n.jpg

And with the bumper installed

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1453538_690085651001824_1684389859_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1469870_690085677668488_1365134950_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1457525_690085721001817_1959680308_n.jpg

There are plenty more photos of the entire build thus far here: https://www.facebook.com/media/set/?set=a.631275600216163.1073741850.230593130284414&type=3

Next week we should be able to get into the fun stuff, some custom fabrication!

Brucker
12-10-2013, 12:03 AM
Before we can start working on a front bumper, we need to strengthen the front cross member/spring hanger/frame section. To complete this we will fabricate a support plate for the area and weld it into place. This will add the needed strength as well as tie everything together neatly.

We begin by cleaning the area in question up and taking down the high spots in the existing welds in order for the new plate to fit properly.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-frc3/1473066_706069909403398_814030327_n.jpg

We then take the necessary measurements for widths and heights and also hole placement. Then lay those out onto our material. The material we went with is 3/16" mild steel.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1461607_706069896070066_1201072805_n.jpg

Then we cut the plate into the rough shape with one of our plasma cutters.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1003789_706069899403399_700547830_n.jpg

Cleaned up the edges and punched the through holes for the bumper mounting hardware

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1461233_706069956070060_1114112503_n.jpg

Mounted the plate into position using the factory hardware for the bumper

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1455856_706069979403391_980147837_n.jpg

And then fully welded the plate into position and cleaned up our welds

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1450228_706077352735987_699228861_n.jpg

Hope to be able to start on the front bumper design and fabrication soon. The shop is still crazy busy and other projects seem to keep taking precedence. The owner also just added another couple things to the "must do" list for us this time around. More details soon :evil:

Brucker
12-17-2013, 08:20 PM
Our client prefers plate style bumpers over most tube style bumpers. But he doesn't like what is currently available on the market (too big and bulky like the ones made by ARB). So he gave us the green light to let our creative shine and dream up and fabricate something just for him.

Here are the few guidelines he gave us:

-must be a plate style bumper
-must have accommodations for some flush mount lightning
-must offer great protection while staying close and tight
-prefers open winch design over it being enclosed
-Use an XRC8000 winch with synthetic line

While trying to take everything into account, we are able to come up with a rough idea of what we are after. Though, keep in mind we are going to be creating this on the fly so things may change as we go. I will let the photos do most of the talking, but will try to highlight some areas with some more explanation. But as always, if you have any questions as to why we did something a certain way or about anything really, just ask.

We start by designing a simple "backbone" for the bumper that will be bolted directly to the frame

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1470089_710341172309605_852867086_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1488276_710341312309591_476211342_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1511234_710341325642923_405107732_n.jpg

We then layout, cut, drill, and bend up a simple winch tray

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1510516_710341442309578_1062913413_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1476174_710341462309576_1973385599_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1461891_710341522309570_1074635618_n.jpg

Test fitting the tray to the backbone

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1526202_710341572309565_96555094_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1476691_710341575642898_1396710673_n.jpg

We then bolt the backbone onto the 4Runner using the factory hardware

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1475964_710341665642889_1351678340_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1488332_710341762309546_1089352784_n.jpg

Brucker
12-17-2013, 11:21 PM
Tack welded the tray onto the backbone

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1510829_710341798976209_2090311260_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1461194_710341818976207_1022879955_n.jpg

Designed and cut the top plates for the wings

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1507606_710341662309556_1574277361_n.jpg

Tack welded a couple risers and the top to each wing into place

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1512609_710341878976201_1163750443_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1476711_710341918976197_1937080513_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1477398_710341932309529_1407937913_n.jpg

Then added the front plate. You notice it's odd shape as it will hold the fairlead and it has provisions cut on the sides for some flush mount LED lighting from Rigid Industries

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/1521721_710341982309524_1169513067_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1501734_710342018976187_1510420665_n.jpg

And a couple more plates fab'ed up and tacked into place on each side. An internal vertical support and the first pieces of the sloped section of the front face.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1522060_710342032309519_1687847254_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1470373_710342078976181_1038691238_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1476265_710342062309516_1351317427_n.jpg

Brucker
12-17-2013, 11:34 PM
Now with the addition of the aluminum hawse fairlead. The front bumper is starting to take shape, though, keep in mind that we are making this one up as we go. This means you might see a few changes as we progress.

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1511922_710342115642844_1660586385_n.jpg

We cut a couple pieces of angle iron for the front face then tack welded the angle into place and modified the front plate to add a slight slope upwards.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1522080_710342172309505_593885372_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1508026_710342288976160_1768672984_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1472757_710342295642826_279614208_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1470391_710342312309491_1878012232_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/997012_710342418976147_181631624_n.jpg

Another set of internal vertical support plates tacked into place on each side.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1463898_710342428976146_985802058_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1476052_710342472309475_99010580_n.jpg

Next piece is cut and fit into place

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/936558_710342522309470_1688114046_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1527128_710342545642801_1683259684_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1483311_710342578976131_2031172430_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/988462_710342588976130_1352840614_n.jpg

imhighlander
12-18-2013, 09:11 AM
Way cool! Excellent progress and thanks again for such a great thread.

mikeyhcrana
12-18-2013, 10:40 AM
How much for another bumper just like that?

It would be so awesome if you sold pieces as a kit one could weld himself!

Brucker
12-18-2013, 04:45 PM
Way cool! Excellent progress and thanks again for such a great thread.

Thank you for the kind words. :beer:

How much for another bumper just like that?

It would be so awesome if you sold pieces as a kit one could weld himself!

As a rule I never reveal what a client has paid for work done. If they feel like sharing, I have no problem with it, but it is up to them. I do however offer estimates or quotations, which are ballpark figures. If you would like a real estimate written up for your vehicle, call me at the shop and I would be happy to do so.

Custom work is expensive, though I have been told I have a fairly low shop rate for Boulder County. My shop rate is $80/hour and I charge for all time and materials. For this bumper, including all design, fabrication, and coating, I will have between 30-50 total hours into it when it is all said and done.

I have no plans to date of ever producing a bumper like this again. It is a custom one-off. To date, I don't offer any product lines or have any plans to. I enjoy doing the custom stuff, so that is what I do. Luckily, I have been able to maintain a full and busy schedule since I started. And hopefully it will stay that way.

If you have the knowledge and abilities it would take to properly weld together a bumper like this from kit form, you should easily be able to make one from scratch, thus, not needing a kit. Everything I have done besides the plate bending could be done with a tape measure, straightedge, drill, cut off disc and grinder (or any other metal cutting equipment), welder, and a sander. I just may use different equipment because I happen to own something that may make one of those processes quicker and/or easier, or I feel more comfortable with one over another. And the plate bending isn't needed. You could just cut and miter and weld everything together.

Hope that this helps.

rover67
12-18-2013, 05:04 PM
Looks sweet! Live dangerously and make the wings of the bumper air tanks!

Brucker
12-18-2013, 11:36 PM
Picking up from where we left off, we add the last couple of inner vertical supports to each side

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1507974_710342778976111_1528624567_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1521345_710342862309436_558326621_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1511413_710342872309435_462758056_n.jpg

With all of the inner pieces tack welded into position, we are able to make the rest of the plates to finish out the front faces.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1524718_710342925642763_1815024697_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1491633_710342965642759_515849044_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1466277_710342978976091_1082442032_n.jpg

The next couple of plates on both sides needed slight bends in them in order to make them fit properly

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1528649_710343025642753_1776960269_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1526422_710343075642748_1381583501_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/600619_710343092309413_83424774_n.jpg

Brucker
12-18-2013, 11:42 PM
The next plates installed on both sides

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1472807_710343162309406_255020396_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1505446_710343178976071_1016271279_n.jpg

And the last set of plates for the front faces tacked into position

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1499554_710343325642723_1587680315_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1489016_710343395642716_1982783897_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1461163_710343405642715_1668692724_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1380118_710343465642709_101568321_n.jpg

imhighlander
12-19-2013, 11:31 AM
Will you be fabbing up a plate-type rear bumper to go with the front, or is client keeping the tube-type on the back from earlier in the thread?

Brucker
12-19-2013, 05:35 PM
Will you be fabbing up a plate-type rear bumper to go with the front, or is client keeping the tube-type on the back from earlier in the thread?

The rear bumper is staying put this time around. The plan is to build a custom one for the rear at a later date when funds allow. As mentioned earlier in the thread, we purchased the TG rear based off it's price compared to it's protection offered. Best bang for the buck. So he won't be out that much once it gets replaced. He would eventually like a custom rear that has a tire carrier, Hi Lift mount, and provisions for jerry cans and the like.

Brucker
12-20-2013, 12:13 AM
The last pieces that we will add while the bumper is on the vehicle are the D ring (or shackle) mounts. Not only will they provide the obvious, they also will provide a LOT of strength and rigidity to the winch tray itself. We use our mill to cut the desired thru hole size.

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1511150_710343648976024_1087132560_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/1528572_710343635642692_639985769_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1471905_710343715642684_1836013565_n.jpg

Smoke flare up once I reopened the coolant line (had it shut off to take a better photo):

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1390535_710343672309355_2031624045_n.jpg

You gotta love it when you get chips like this. Not only do you know the speeds and feeds are set right, you know there wasn't any chatter and cleanup is SO much easier.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1473018_710343705642685_182926451_n.jpg

The plates fresh out off the mill:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1521584_710343735642682_345496642_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1470182_710343752309347_306776497_n.jpg

We didn't have the right tubing in stock for the next parts. So instead of ordering a whole stick of material and having to wait on it's delivery of next week, we decided to cut our own. We happened to have some thicker walled tubing of the same OD which we could easily modify. So we put a length into one of our lathes and went to work:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1511264_710343548976034_839480087_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1503244_710343552309367_2037658700_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1486655_710343615642694_920294626_n.jpg

Brucker
12-20-2013, 12:22 AM
With the tubing now having the correct ID, we pull it out of the lathe and part off the two pieces we need using a horizontal band saw so the lathe could get back to work on making the parts we had interrupted.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1483104_710343798976009_338388978_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1526939_710343822309340_1110550327_n.jpg

The left over section of tubing shows just how much material we needed to remove:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1508197_710343832309339_1865977359_n.jpg

Then insert the tubing into the plates that were just made

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1525524_710343868976002_928455029_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1487448_710343888976000_640403867_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/559876_710343898975999_1766904477_n.jpg

And then welded them together

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1510913_710344132309309_1173294788_n.jpg

The hangers will be able to except the more common sizes of D rings in this industry, 5/8", 3/4", and 7/8" shackles

https://scontent-a-dfw.xx.fbcdn.net/hphotos-frc3/1511300_710343848976004_1631471403_n.jpg

Now we are able to tack weld them into place

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1477364_710344312309291_92335923_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1511380_710344255642630_590062374_n.jpg

Shotshell
12-21-2013, 12:44 AM
Looks great. I like it. :thumb:

Brucker
12-28-2013, 02:57 AM
Looks great. I like it. :thumb:

Thanks for the kind words :beer:

Brucker
12-28-2013, 02:58 AM
The majority of the work left on the front bumper will be done with it off of the vehicle. With it removed and sitting of the fab table, you are able to see the inner support structure better.

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc1/1486610_710344428975946_168311408_n.jpg

Our focus turns towards making the mounting plates for the flush mount lighting from Rigid Industries. We have used their products on multiple builds now and they have yet to disappoint. Some of the best lighting, if not the best, you can buy. Here is a shot from an earlier build showing what one of their 50" light bars can do:

http://sphotos.xx.fbcdn.net/hphotos-ash4/425567_10151307905410075_543505074_22845089_2095277721_n.jpg

On this bumper we will be using a set of their Dually D2 driving lights. They won't pack quite the punch as the 50" above, but should produce more than enough illumination for our needs. Here is one fresh out of the package:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1524924_710346188975770_834608737_n.jpg

We make a set of mounting plates

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash3/1525117_710344418975947_1568484764_n.jpg

Then bend up some round rod to use as spacers so the lights will be truly flush with the front face of the bumper

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/524763_710342238976165_1277437870_n.jpg

We make the final cuts to the plates and start to fit the rod

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/1497682_710344555642600_872426718_n.jpg

Once the rod is welded to the plates, we smooth the edges

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1468570_710344582309264_87988876_n.jpg

Added cage nuts

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1499478_710344762309246_879296054_n.jpg

And test fit them into place

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/993542_710344688975920_1673371959_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1466313_710344782309244_54109969_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1484250_710344825642573_1592493150_n.jpg

We then clamp the bumper to the fab table and tack weld the mounting plates and front face plate into place

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1509733_710344778975911_1336056166_n.jpg

imhighlander
12-28-2013, 09:12 PM
Beefy! I dig it.

AxleIke
12-29-2013, 01:24 PM
LOVE the flush mounted light work. That is a killer idea.

BTW, I'm looking at some lighting options. would you mind posting up pics of these small guys when you get them all done, similar to the light bar? Just so we can see how far and bright they are. I really like the idea of small compact lights.

Cheers!

Brucker
12-30-2013, 12:17 AM
Beefy! I dig it.

LOVE the flush mounted light work. That is a killer idea.

Thanks for the kind words

Brucker
12-30-2013, 12:18 AM
With the bumper still clamped to the fab table, we cut another set of plates to be used as inner gusseting. These will be positioned along the front faces and the winch tray. It will give added support if/when we decide to put a hoop onto the bumper for extra winch and radiator protection.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1526089_710345012309221_266169523_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1456531_710345015642554_325087842_n.jpg

The next steps would include finishing the backbone of the bumper. This will require a slight modification to what already exists. So we need to unclamp it from the fab table. After doing so, I decided to add in the caps for the angle iron pieces on the front face. So I cut the 4 pieces needed and tack welded them into place

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1477691_710345112309211_611344326_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-ash4/1501694_710345095642546_946848935_n.jpg

Then made the slight modification to the existing backbone structure. Before:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1528490_710344518975937_1748691334_n.jpg

After:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1513327_710345142309208_340439767_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/555114_710345155642540_1995413489_n.jpg

Then bent up some round rod to finish out the top of the front face. Once fully welded into place and getting smoothed out, it will not only add strength, but a clean, finished look of a rolled edge. Here is the rod tack welded into position

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/1512602_710345192309203_559190980_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1471859_710345215642534_78781254_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1471090_710345165642539_1647409123_n.jpg

After the addition of the new pieces, we are ready to to start on the backbone once again. We once again clamp the bumper to the fab table

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1471101_710345235642532_1317518304_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/1017242_710345255642530_2076526839_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/960244_710345272309195_807515199_n.jpg

Brucker
12-30-2013, 12:30 AM
Continuing on with the backbone, we cut and fit into place the next couple sections

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/282912_710345285642527_1427676694_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1505151_710345305642525_1777742079_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/t1/997000_710345348975854_104024889_n.jpg

Then a couple more until the backbone is finished out.

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1521613_710345402309182_1718137494_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn2/1526691_710345425642513_1985720334_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1461143_710345495642506_1047107097_n.jpg

Then I fully welded the inside of the bumper together. This will allow us to be able to safely sand out/smooth out all the visible welds without losing any strength. Once the bumper had fully cooled, we pull it off the fab table and install it once again onto the 4Runner. This should be our last test fit if it didn't wrap during welding and if we got all our frame and body clearances right. Here it is installed

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1471113_710345552309167_1266396390_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc1/1484140_710345678975821_2029632440_n.jpg

https://scontent-a-dfw.xx.fbcdn.net/hphotos-ash3/1476544_710345725642483_948395503_n.jpg

And one showing that the backside clears:

https://scontent-a-dfw.xx.fbcdn.net/hphotos-prn1/1486747_710345902309132_1817474680_n.jpg

simps80
01-01-2014, 01:23 AM
Fun build to watch!!!

Brucker
01-06-2014, 01:00 AM
Everything looked good on the test fitting so we once again removed the bumper and clamped it to the fab table. After prepping the backbone we begin welding it solid.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1504956_710346078975781_1830712230_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1483415_710346098975779_1640610439_n.jpg

Once the backbone was fully welded together and had cooled, we drilled a hole in each side of the winch tray to accommodate the wiring for the lighting once the bottom is plated.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/936567_710346148975774_2118383730_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1486758_710346112309111_995421906_n.jpg

Now we could finish plating the bumper. We repositioned the bumper on the fab table and clamped it into place. Then took measurements for and cut and tack welded the first set of bottom plates.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/1504040_710346208975768_746698980_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1517541_710346235642432_736952404_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1476272_710346258975763_604737987_n.jpg

We then continued this process:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/600657_710346298975759_746595220_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1524918_710346358975753_383400395_n.jpg

The next couple sets of plates needed bends for the correct fitment

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1496663_710346462309076_387535755_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1472814_710346548975734_1529771236_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1465269_710346648975724_2125908647_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/994696_710346685642387_1027520342_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-frc3/1390767_710346708975718_1405569667_n.jpg

Brucker
01-06-2014, 01:12 AM
With the bumper still clamped to the fab table we fully welded the bottom plates in. Once cool we removed the clamps to reposition it for final welding.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1512636_710346732309049_1983165049_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1513241_710346768975712_1721419454_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1524601_710346788975710_2015264094_n.jpg

We clamped two pieces of thick tubing to the front plate (one on the front and one on the rear, pinching the front plate between them) to keep it from warping when we weld the round rod

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1471257_710346808975708_1521401501_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/1521687_710346828975706_770164029_n.jpg

Then continued to reposition and clamp until the bumper was fully welded inside and out

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/994423_710346858975703_412898490_n.jpg

And started the sanding process:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash4/1484135_710346878975701_1654440260_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1476150_710346888975700_1061611333_n.jpg

Brucker
01-06-2014, 01:18 AM
Then once the majority of the rough sanding was completed, I once again bolted it onto the 4Runner for a quick look:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/946085_710347042309018_468365425_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-prn2/988416_710347135642342_902376401_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1017215_710347168975672_1251866555_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/1477671_710346908975698_1537981448_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/486685_710347188975670_346532557_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1488120_710346992309023_1417564286_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1471784_710347028975686_1520251873_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/960119_710347212309001_1236554536_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1497616_710347222309000_1097920403_n.jpg

MDH33
01-06-2014, 08:43 AM
That's looking fantastic. :thumb:

My only critique would be regarding the box the winch sits in. Seems like it needs a big drain hole. I could see that filling up with mud, water gravel, etc. with no easy way to keep it cleared out.

Brucker
01-06-2014, 05:11 PM
That's looking fantastic. :thumb:

Thanks for the kind words :beer:

My only critique would be regarding the box the winch sits in. Seems like it needs a big drain hole. I could see that filling up with mud, water gravel, etc. with no easy way to keep it cleared out.

Good catch! If that's your only critique thus far, you must not be looking close enough ;)

While the major fabrication of the bumper is complete, it is a long way from being finished. As was pointed out, it still needs drain hole(s), as well as weld washers around the winch mounting holes, lots more sanding/clean up, the possible addition of a hood hoop/stinger, and we will be tying in the back of the bumper into the shock hoops at some point.

Shotshell
01-06-2014, 05:15 PM
That looks sick! :thumb: I like it, a lot.

Brucker
01-06-2014, 11:49 PM
That looks sick! :thumb: I like it, a lot.

Thanks.

One of the main goals in fabricating the bumper was to try to keep the added weight to a minimum. Some tube bumpers can weigh as little as 60 lbs, and knowing that some plate bumpers can come close to 200 lbs. Here is how ours' fared.

Before to show the scale was tared correctly:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1525589_720683637942025_889398875_n.jpg

With it sitting on the scale:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1514981_720683734608682_1755004109_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1511168_720683751275347_60582698_n.jpg

Coming in at 93 lbs makes us happy. A tad heavier than we were shooting for, but well under the ARB at 160 lbs and even better than Body Amour Products plate style bumper which comes in right at 100 lbs.

Brucker
01-06-2014, 11:52 PM
Also test fit the lights today. Think they should work well:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/1557516_720683171275405_103484830_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1507081_720683217942067_1281898800_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/399223_720683067942082_1015078175_n.jpg

AxleIke
01-07-2014, 02:41 PM
Looks fantastic!!!

What do you use to grind? Flapwheels, hard wheels, paper discs, etc? I am always looking for new ways to smooth things out.

Brucker
01-07-2014, 04:45 PM
Looks fantastic!!!

What do you use to grind? Flapwheels, hard wheels, paper discs, etc? I am always looking for new ways to smooth things out.

Thank you for the kind words.

I usually use one of my large Makita 7" or 9" angle grinders outfitted with 7" flap disc from Heleta (use the 7" because I haven't found a 9" one). The bigger grinders are a lot heavier, but it doesn't take as much force or time to take the material off, so your arms don't really get tired quicker. And then I switch out to a complete 4.5" set up for the rest of the rough sanding. Then use one or more different styles of DA sanders for the finish work.

Here is a look at the difference between the more common 4.5" flap disc and the larger 7":

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1476025_712877412055981_2031860868_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn2/1472990_712877792055943_434167594_n.jpg

https://scontent-b-dfw.xx.fbcdn.net/hphotos-prn1/1535557_712877762055946_1997672163_n.jpg

And one showing the difference between a 4.5" Makita vs a 7" one:

https://scontent-b-dfw.xx.fbcdn.net/hphotos-frc3/1506692_712878668722522_172252010_n.jpg

Brucker
01-16-2014, 11:30 PM
Next up is the body work, cage and lining the interior with Herculiner. All of which will require most of the interior, as well as the top to be removed. We start with the top. Simply rig the top to be lifted by our overhead hoist, and lift up and away:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/44463_725777490765973_1931428313_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1482781_725777517432637_717111043_n.jpg

Like most beautiful woman do, it's looking good topless:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/1601132_725777914099264_1335439032_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/37772_725777947432594_1687642143_n.jpg

A quick glace at the top shows how dirty things can get with metal dust flying around constantly:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/1505996_725777897432599_2099443265_n.jpg

Ahh, good ol' brown shag carpeting, can't wait to remove it:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1530526_725777917432597_1628885326_n.jpg

We remove the rest of the interior and doors:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn2/t1/1510846_725777990765923_1004347704_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash4/t1/1489203_725778107432578_846354222_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1560384_725778280765894_1592956147_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/1017139_725778344099221_2145051789_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/t1/1531606_725778354099220_490647246_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/1525687_725778410765881_562486899_n.jpg

Brucker
01-26-2014, 11:43 PM
Time for some cage work. This time around, the client wanted a simple 4 point interior cage. By 4 point, we are referring to the amount of points the cage will be tied into the frame. It will be constructed out of DOM round tubing and tied into the frame using bushings. We will also be tying in the factory roll bar to the new tube work, stiffening the entire chassis. Eventually the plan is to eliminate the factory portions with new DOM throughout and adding 2 to 4 more frame tie in points.

Start off by making a few different sets of cage feet. Two sets for the A pillar and two sets for the B pillar; an interior set at each pillar as well as an exterior set. The difference between the interior plates and the exterior ones are the length and width dimensions. Having one side lager than the other will help keep the cage from easily shearing through the body during impact. Below we show on set of cage feet.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1014003_728624633814592_1934650773_n.jpg

Then position the plates, layout for the through holes, and drill the 4 holes at each location.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1016243_728624547147934_2118349560_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/t1/1383760_728624567147932_1778391495_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn2/t1/1545669_728624650481257_872068631_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/1551581_728624683814587_2061849872_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/1545580_728624763814579_1053367047_n.jpg

Taking into account the very limited interior space, and the fact that the client wants to be able to still be able to fully use his seats (including being able to still flip the back seat down, completely flat), we bend up the first bars. The floor bars will be just that. They will connect the A pillar to the B pillar on each side along the floor. The rest of the cage will then be built off these tubes. After bending up the bars we begin to fit them into place:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/1625626_730479806962408_22212464_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/1555386_730479766962412_92766138_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1010388_730479866962402_1876699269_n.jpg

Once both sides are fitted properly, we pull the seats again, and weld the bars to the plates as much as space allows.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-frc3/t1/996572_730479920295730_1584041605_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc1/1660666_730479930295729_1490644356_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/10187_730479996962389_1225923988_n.jpg

Brucker
01-26-2014, 11:44 PM
Once the bars have cooled enough, we unbolt and remove them for the vehicle and finish welding them solid. He is a photo of the two bars once fully welded, cleaned up, and ready for install. You will notice each bar is bent in a different shape to accommodate each side's different mounting brackets.

https://scontent-a-sjc.xx.fbcdn.net/hphotos-frc3/t1/1607106_730480330295689_700417838_n.jpg

Then we install the bars into position

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/15633_730480396962349_336012622_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/t1/1604650_730480443629011_1881312693_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc1/t1/1001375_730480480295674_115030_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/1480630_730480533629002_1529767114_n.jpg

With the door and bars installed, you can easily see how tight to the door the finished bars are:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/1536447_730480516962337_998104829_n.jpg

Next item was the main hoop or B pillar hoop. All bent up, notched and ready for install:

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/1549358_730480696962319_1464710731_n.jpg

You will notice how again, each leg is different to fit as tight as possible and allow full use of the front and rear seats:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/1656043_730480730295649_813279659_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/1622827_730480763628979_17302141_n.jpg

Tack welded into position

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc1/t1/484849_730480786962310_1168041422_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc3/t1/1497110_730480806962308_1722328396_n.jpg

Folded down rear seat still works

https://scontent-b-sjc.xx.fbcdn.net/hphotos-frc1/t1/1654295_730480953628960_569585090_n.jpg

Brucker
01-26-2014, 11:44 PM
We prep a couple areas on the factory roll bar where we are going to tie in the new tube work.

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/t1/1621780_730481096962279_1848406646_n.jpg

Then bend up and notch a couple top bars to go between the B pillar and the factory roll bar and tack them into place:

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1010386_730481210295601_1185672833_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-prn1/t1/1546354_730481220295600_1988155490_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn1/1017452_730481240295598_1396814275_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/t1/1560681_730481316962257_863569571_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-prn2/t1/1780671_730481343628921_1328348259_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/t1/522461_730481386962250_14925917_n.jpg

Then cut and notched a couple gusset bars for the rear and tack welded them into position:

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1546343_730481436962245_1365178851_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-ash3/t1/1560420_730481463628909_1375026975_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/1011620_730481500295572_246795377_n.jpg

https://scontent-b-sjc.xx.fbcdn.net/hphotos-prn2/1623763_730481573628898_1495496322_n.jpg

https://scontent-a-sjc.xx.fbcdn.net/hphotos-ash3/t1/1653561_730481536962235_791567834_n.jpg

imhighlander
01-29-2014, 09:26 AM
Beautiful work!

AxleIke
01-29-2014, 10:32 AM
Looks good, but I'd stick with the high pile carpet. Totally rad! :D

DaveInDenver
01-29-2014, 10:51 AM
Nice work. Bumper looks great and less bulky than an ARB. I prefer the bull bar because I wanted front end protection (and God knows having been in a couple of accidents they /do/ the job of preventing damage to the hood, grill and radiator).

For reference the standard issue ARB for my '91 IFS was about 80 lbs before putting a winch in it, the 140 lbs is I believe a fully loaded ARB with the winch. That's at least about what mine weights with an XD9000 and synthetic rope. Since you've eliminated the top hoops you've got the equivalent steel in the bracing, so it should be uber substantial.

Brucker
01-29-2014, 02:18 PM
For reference the standard issue ARB for my '91 IFS was about 80 lbs before putting a winch in it, the 140 lbs is I believe a fully loaded ARB with the winch. That's at least about what mine weights with an XD9000 and synthetic rope. Since you've eliminated the top hoops you've got the equivalent steel in the bracing, so it should be uber substantial.

Thanks. Though the last 3 ARB bumpers that came through my shop all were between 150-165 lbs shipping weight, which didn't include any accessories like lights or winch. And that weight is also what ARB and TransAmerican lists most of their fronts at for shipping. I haven't brought one in for a 1st gen so they might be lighter, though yours isn't a first generation either so who knows? And I would honestly have to check if they make one for the first gens.

We were shooting for around 80 lbs before any accessories. Came in a tad high (13 lbs over) but we are still happy. There may still be a hoop added to the top of the bumper but that depends on the owners tastes. We actually played with a couple different styles (if you follow us on Facebook https://www.facebook.com/BruckerBrothersLtd, you would have seen a couple different attempts at fitting some hoops to it) and we couldn't find one that the owner was happy with yet. He for now has taken that off the build sheet, but that honestly seems to be changing everyday.

Brucker
01-29-2014, 02:21 PM
Beautiful work!

Looks good, but I'd stick with the high pile carpet. Totally rad! :D

Thanks for the kind words. The shop is crazy busy as always and I need to make some time to go through all the photos so I can update this thread further. Hope to be able to before the weeks out.

DaveInDenver
01-29-2014, 03:32 PM
Thanks. Though the last 3 ARB bumpers that came through my shop all were between 150-165 lbs shipping weight, which didn't include any accessories like lights or winch. And that weight is also what ARB and TransAmerican lists most of their fronts at for shipping. I haven't brought one in for a 1st gen so they might be lighter, though yours isn't a first generation either so who knows? And I would honestly have to check if they make one for the first gens.

We were shooting for around 80 lbs before any accessories. Came in a tad high (13 lbs over) but we are still happy. There may still be a hoop added to the top of the bumper but that depends on the owners tastes. We actually played with a couple different styles (if you follow us on Facebook https://www.facebook.com/BruckerBrothersLtd, you would have seen a couple different attempts at fitting some hoops to it) and we couldn't find one that the owner was happy with yet. He for now has taken that off the build sheet, but that honestly seems to be changing everyday.
You could very well be right, I'm using the 'man-calibrated' bathroom scale method. ARB does (or did, no idea if they still do) make a bumper for the 84-88 trucks but not for the 1st gen 4WD 79-83 AFAIK.

Brucker
01-31-2014, 12:10 AM
Finally found a little more time to go through some more of the photos so I can update this thread.

Bent up and notched the driver's side A pillar/door bar.

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1/1604910_732520443425011_2040543886_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/t1/1546118_732520480091674_1353929041_n.jpg

Tack welded into position

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/t1/1610049_732521200091602_1294176663_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/t1/1796492_732521170091605_958847058_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/t1/1506699_732521143424941_1272078801_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-frc1/t1/1185159_732521176758271_1335807590_n.jpg

Before we could move on to the passenger side, we needed to remove the factory grab handle. And since we were dismantling something already we also removed factory rear view mirror. This will be replaced by a more modern unit which features a built in compass and temperature gauge. We will be filling in the holes that will be left of with small sheet metal plates.

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn1/t1/1012059_732521340091588_94550514_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-ash3/t1/1005799_732521346758254_1566200274_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash3/t1/1621762_732522150091507_1486330736_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/t1/1622871_732522166758172_1805346615_n.jpg

Brucker
01-31-2014, 12:11 AM
Passenger side A pillar/door bar bent up and notched, ready for install:

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash3/t1/1689343_732521763424879_1573398437_n.jpg

Tack welded into position:

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/t1/1551586_732521750091547_925477451_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-ash3/t1/1621919_732521793424876_353252897_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn1/t1/1622199_732521773424878_902552110_n.jpg

The next piece needed would be the top windshield cross bar. We rolled and then notched a tube to fit. Here it is pictured next to a straight length for reference

https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/t1/1560756_732522776758111_1617864000_n.jpg

Then tack welded the tube into place:

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-frc3/t1/1779289_732523336758055_1756641986_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-ash3/t1/1795541_732523393424716_1300647601_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn1/t1/149337_732523296758059_1308431017_n.jpg

Brucker
01-31-2014, 12:11 AM
Bent up and notched the dash bar

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/t1/1798127_732523760091346_1855917736_n.jpg

And tack welded that into place:

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn1/t1/1560670_732523800091342_560051765_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.net/hphotos-ak-frc3/t1/1499656_732523836758005_585980143_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/t1/1779240_732523850091337_2044532775_n.jpg

https://scontent-a-ord.xx.fbcdn.net/hphotos-prn2/t1/1743581_732523803424675_1573304143_n.jpg

And then bent, notched and tacked into place the center roof spreader. Again, bent to allow for the most amount of clearance (headroom) possible:

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1/1661834_732524323424623_437970201_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-frc3/t1/1506887_732524316757957_245817658_n.jpg

https://scontent-b-ord.xx.fbcdn.net/hphotos-prn2/t1/1656152_732524313424624_976940876_n.jpg

liveoffroad
02-05-2014, 10:44 AM
wow, that is one of the cleanest interior cages i've seen, well done! i dont have any experience building cages, but i'm wondering how strong it is w/o being tied into the frame?

Brucker
02-05-2014, 02:21 PM
wow, that is one of the cleanest interior cages i've seen, well done! i dont have any experience building cages, but i'm wondering how strong it is w/o being tied into the frame?

Thank you for the kind words. As for being tied into the frame, I just haven't gotten there yet. Heck the cage isn't even fully welded together yet. If you read back (I know, lots to go through) I already went over the cage plan and specs. Here is what I wrote back on the last page in post #74:

Time for some cage work. This time around, the client wanted a simple 4 point interior cage. By 4 point, we are referring to the amount of points the cage will be tied into the frame. It will be constructed out of DOM round tubing and tied into the frame using bushings. We will also be tying in the factory roll bar to the new tube work, stiffening the entire chassis. Eventually the plan is to eliminate the factory portions with new DOM throughout and adding 2 to 4 more frame tie in points.

Hope that this helps.

Hulk
02-05-2014, 05:51 PM
It's so tightly fitted, I've been wondering if you'll be able to paint it once it's all done.

liveoffroad
02-07-2014, 09:13 AM
Hope that this helps.
It does, thank you... looking forward to see how this turns out.

rover67
02-07-2014, 09:29 AM
It's so tightly fitted, I've been wondering if you'll be able to weld it once it's all done.

fixed it for you

Brucker
02-07-2014, 04:48 PM
It's so tightly fitted, I've been wondering if you'll be able to paint/weld it once it's all done.

fixed it for you

Crap, never thought about having to fully weld all the joints! Whatever will we do? :confused:

Honestly though, I can't give away all my fabrication secrets. If I did there wouldn't be a need for me or my business anymore.

J/K If you believe that load of crap, I got some great land to sell ya :D But I do firmly believe that being able to easily answer questions like this is one of the many reasons me and my business have been able to stay as busy as we do.

As for welding the cage fully, if I didn't, it wouldn't be a proper or even close to safe, cage. Never, and I mean never, think it is ok to skip welding any part of any joint when it comes to structural cages.

The tube work will be welded in certain areas, then disassembled into various larger pieces (rear spreaders, then B pillar, the A pillar complete with cross bars and center spreader, the floor bars will be the last pieces out), then the welding of the unreachable areas will take place. The different pieces will be coated in primer, then paint (except for the areas that will be effected by any welding still needed), then reinstalled, finished welded, and finished painted. The cage will not be able to be removed from the vehicle once it is fully welded, without cutting something apart.

Hope that this answers your questions.

rover67
02-07-2014, 09:49 PM
yeah wasn't saying you weren't going to weld it all just that it is not easy.

I am familiar with the type of work.

Brucker
02-07-2014, 11:51 PM
yeah wasn't saying you weren't going to weld it all just that it is not easy.

I am familiar with the type of work.

Hmmm... My mistake then. I thought I answered your question of, "been wondering if you'll be able to weld it once it's all done?". To which I based my response.

The work is actually fairly easy. As easy as any tube work really. So I guess you mean that there are just more steps involved than say fabricating a cage for something without a top. Which you would be correct. But there really is not that many more steps.