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  #41  
Old 12-17-2013, 07:20 PM
Brucker Brucker is offline
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Default Front winch bumper

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







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







Test fitting the tray to the backbone





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



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  #42  
Old 12-17-2013, 10:21 PM
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Tack welded the tray onto the backbone





Designed and cut the top plates for the wings



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







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





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.





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  #43  
Old 12-17-2013, 10:34 PM
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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.



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.











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





Next piece is cut and fit into place







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  #44  
Old 12-18-2013, 08:11 AM
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imhighlander imhighlander is offline
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Way cool! Excellent progress and thanks again for such a great thread.
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  #45  
Old 12-18-2013, 09:40 AM
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How much for another bumper just like that?

It would be so awesome if you sold pieces as a kit one could weld himself!
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  #46  
Old 12-18-2013, 03:45 PM
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Quote:
Originally Posted by imhighlander View Post
Way cool! Excellent progress and thanks again for such a great thread.
Thank you for the kind words.

Quote:
Originally Posted by mikeyhcrana View Post
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.
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  #47  
Old 12-18-2013, 04:04 PM
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rover67 rover67 is offline
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Looks sweet! Live dangerously and make the wings of the bumper air tanks!
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  #48  
Old 12-18-2013, 10:36 PM
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Picking up from where we left off, we add the last couple of inner vertical supports to each side







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.







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





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  #49  
Old 12-18-2013, 10:42 PM
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The next plates installed on both sides





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







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  #50  
Old 12-19-2013, 10:31 AM
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imhighlander imhighlander is offline
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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?
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