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Old 09-25-2012, 04:36 PM
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coax coax is offline
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Join Date: Oct 2008
Location: Estes Park
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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)
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Old 09-25-2012, 05:20 PM
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corsair23 corsair23 is offline
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Join Date: Jul 2006
Location: Littleton
Posts: 8,684

Very nice Corey!!

Jeff Z. (the "not quite as skinny" one)
TLCA #17037
'97 LX450 - aka "The Whale"
'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
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Old 09-25-2012, 09:54 PM
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RedCreeper RedCreeper is offline
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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.....
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Old 09-25-2012, 11:18 PM
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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.
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Old 09-26-2012, 07:08 AM
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RicardoJM RicardoJM is offline
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Location: Centennial, CO
Posts: 2,363

That is pretty sweet.
Ricardo Maestas - Bio Page
1999 LX 470
SOLD - 1971 FJ-40
TLCA #18941
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Old 09-26-2012, 08:13 AM
SteveH SteveH is offline
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Join Date: Aug 2006
Location: Colo Springs
Posts: 1,495

That was a ton of work!
Steve H.
Colo Springs, CO
'78 FJ40, '89 FJ62, '98 4Runner
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Old 09-26-2012, 05:57 PM
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Rzeppa Rzeppa is offline
Cruise Moab Co-Chairman & RS Secretary
Join Date: Aug 2005
Location: Kittredge CO, USA
Posts: 5,896

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
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Old 09-26-2012, 07:03 PM
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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
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