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  #61  
Old 12-29-2013, 11:30 PM
Brucker Brucker is offline
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Continuing on with the backbone, we cut and fit into place the next couple sections







Then a couple more until the backbone is finished out.







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







And one showing that the backside clears:

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  #62  
Old 01-01-2014, 12:23 AM
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simps80 simps80 is offline
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Fun build to watch!!!
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  #63  
Old 01-06-2014, 12:00 AM
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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.





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.





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.







We then continued this process:





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









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  #64  
Old 01-06-2014, 12:12 AM
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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.







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





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



And started the sanding process:



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  #65  
Old 01-06-2014, 12:18 AM
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Then once the majority of the rough sanding was completed, I once again bolted it onto the 4Runner for a quick look:

















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  #66  
Old 01-06-2014, 07:43 AM
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That's looking fantastic.

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.
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  #67  
Old 01-06-2014, 04:11 PM
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Quote:
Originally Posted by MDH33 View Post
That's looking fantastic.
Thanks for the kind words

Quote:
Originally Posted by MDH33 View Post
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.
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  #68  
Old 01-06-2014, 04:15 PM
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That looks sick! I like it, a lot.
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  #69  
Old 01-06-2014, 10:49 PM
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Quote:
Originally Posted by Shotshell View Post
That looks sick! 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:



With it sitting on the scale:





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.
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  #70  
Old 01-06-2014, 10:52 PM
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Also test fit the lights today. Think they should work well:





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