Rising Sun Member Forums  

Go Back   Rising Sun Member Forums > Toyota 4x4 > General Tech Forum

Thread Tools
Old 09-25-2012, 05:36 PM
coax's Avatar
coax coax is offline
Hard Core 4+
Join Date: Oct 2008
Location: Estes Park
Posts: 750
Default My First Welding Project AKA Rear Bumper Build

For a long time I've wanted a better way to carry gas than on the roof. The long term plan also includes storage underneath where the spare was for tools/oil/etc that I don't access often and would rather not keep in the interior.

I wanted a bumper that:
1. Was bolt on.
2. Not built for serious rock crawling, but would provide a happy medium of protection and carrying capacity vs. the weight penalty. (Doesn't need to hold a 39" tire, don't need to support the full weight of the cruiser if its up against a rock, etc)

From my limited research there either wasn't anything in this category out there or it was going to be hard to come by. Either way, I decided I'd give it a go and attempt to build one. There are a ton of builds on Mud and I just kinda took pieces and parts from a bunch of different ones to come up with something.

Ended up taking ton more time than I first estimated. Oh well, I like projecting and whatnot.

Its a mix of 1/8, 1/4 and other random scraps. Got the spindles from 4x4labs w/ sleeves. Latches and spring pins from mcmaster.

The recovery points have a 5/16" plate that goes through the bumper main box, and then additional 1/4 pieces welded on the sides.

Overall the construction and welding went OK. I designed most of it to be as "redundant" as possible. (IE each arm is drilled through and slipped over the spindle as opposed to just welded on there.) I also practiced with some gussets and other small bits to help beef it up where thin metal was used and get some practice. The welds came out ok. Not too consistent yet. Oh well! Pretty much just turned up the Promig 140 to the highest setting and used flux core. Other tools used were an angle grinder, chop saw, and drill press for the larger holes. Thats pretty much it. Was lucky to borrow a friends shop for the duration cause I work slow!

The spring pins hold the bumper both closed and open at maybe a 110 degree angle. The tire and gas cans are angled back just a bit. The sleeve for the spindle was 1/8" welded into the 3x6 box, with an additional 1/4 plate in the middle for strength.

Paint was just some rustoleum brush on....Not very durable at all. Will have to figure something else out long term.

I spent a few days down in beef basin/elephant hill and the bumper did great. Didn't take any big hits but it held together. Time will tell the story on durability, though even with some pretty good bumps and whatnot I didn't notice any movement on the tire.

The Test Run!

'97 lx450, 170k, factory lockers, ome 850/863, 285's, 4 working doors(1 more than the old fj55 )
'74 project pig (sold)
Reply With Quote
Old 09-25-2012, 06:20 PM
corsair23's Avatar
corsair23 corsair23 is offline
Rising Sun Member
Join Date: Jul 2006
Location: Littleton
Posts: 8,684

Very nice Corey!!

Jeff Z. (the "not quite as skinny" one)
TLCA #17037
'07 UZJ100
'97 FZJ80 Antique Sage AE #267, stock
12/74 FJ40, 2F, SM420, 4" Lift, ARBs, 33" MTRs


"...anything else i can do for you guys, how about i wash your car or mow your lawn while you figure out your firewall system? I am now boarderline insane/unibomber." Kipper

"That assumes I'm even capable of pulling and stabbing..." Jacket

"I really like having a detachable unit." Beater
Reply With Quote
Old 09-25-2012, 10:54 PM
RedCreeper's Avatar
RedCreeper RedCreeper is offline
Hard Core 4+
Join Date: May 2008
Location: Firestone, CO
Posts: 987
Send a message via AIM to RedCreeper

nice work
Kenny Jones
TLCA #19056
82 Scrambler (Scraps)
81 Scrambler (Sassy)
07.5 Dodge Ram 2500
69 Maro... next project when the Jeeps get done.....
Reply With Quote
Old 09-26-2012, 12:18 AM
ScooterFJ40's Avatar
ScooterFJ40 ScooterFJ40 is offline
Rock Stacker
Join Date: Aug 2012
Location: Castle Rock
Posts: 27

I've seen a lot worse welds and designs

Way to improvise!
1988 Toyota Xtra Cab, Four Linked, 22RE, 40's at the moment.
Reply With Quote
Old 09-26-2012, 08:08 AM
RicardoJM's Avatar
RicardoJM RicardoJM is offline
Rising Sun Member
Join Date: Jul 2007
Location: Centennial, CO
Posts: 2,396

That is pretty sweet.
Ricardo Maestas - Bio Page
1999 LX 470
SOLD - 1971 FJ-40
TLCA #18941
Reply With Quote
Old 09-26-2012, 09:13 AM
SteveH SteveH is offline
Hard Core 4+
Join Date: Aug 2006
Location: Colo Springs
Posts: 1,835

That was a ton of work!
Steve H. - KE0KNH
Colo Springs, CO
'78 FJ40, '89 FJ62, '98 4Runner
Reply With Quote
Old 09-26-2012, 06:57 PM
Rzeppa's Avatar
Rzeppa Rzeppa is offline
Cruise Moab Chairman
Join Date: Aug 2005
Location: Kittredge CO, USA
Posts: 6,708

Very nice! I need to do something similar for my 60; the only bolt-on ones I can find are Kay-Mar and 4+, and both of those have stuff I am not cranked up about. I definitely need that wrap-around corner protect as I already buggered up my sheet metal on Jenny Creek.
Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
Reply With Quote
Old 09-26-2012, 08:03 PM
TIMZTOY's Avatar
Hard Core 4+
Join Date: Apr 2009
Location: Denver
Posts: 1,914

very nice..
TLCA # 20314
84 Hilux, 22re Conversion, 63" chevy rears, Rears up front, Bobbed bed, duel e-lockers, 5.29's, 35" Ground Hogs low compression
Step by Step Bed Bob
Reply With Quote

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

All times are GMT -6. The time now is 10:19 AM.

Powered by vBulletin® Version 3.7.1
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.