4Runner rear bumper build [Archive] - Overland Canada Forums

Jeremy

01-24-2009, 02:26 PM

Well I finally got off my butt and started the first steps toward building a rear bumper and tire carrier system.

Goal: Rear end protection and equipment storage system.

The rear bumper on the 90-95 4runners (as well as the 96-02) is made out of very thin stamped sheet metal. The bumpers are also attached to the body not the frame. So needless to say if you hit something you are not only damaging the bumper but the body too. The stock bumpers are also very prone to rust, my truck is in its 2nd bumper and end caps.

Today I started by removing the spare and the rear bumper to see what I was dealing with. The rear bumper came off with out a hitch and am surprised that not one of the bolt broke off. When I took off the bumper I also took with it about 10lbs of Whipsaw mud lol.

After removing the bumper I was able to see what I was working with. The rear gate on my truck works like a PU tail gate so it opens down. The good thing it that one I got bumper off I was able to see that the gate dose not go any lower than the bottom seam when its closed.

Now the problem that I knew I was going to run into was the frame in the back is higher than the gate. So I will need to make some kind of dog leg to get the bumper firmly attached to the frame. Looking from the bottom of the tailgate to the bottom of the frame rail looks about even. If I still had coils it would be an easy way to mount it just take some square stock and run it straight out. With the shackles mounted there that's not an option. I have two choices as I can see it. First is to take some rectangle stock and put it in the frame end and then get creative with angles. The other is to take some 1/2 plate and weld it to wards the front of the shackle mounts and have them stick out the sides from there I can build an attachment method from there.

I want to keep the ability to remove the bumper for maintenance or changes. So I will need to have it attached to brackets with grade 8 hardware.

So now I need to design some form of mounting system.

I will be updating this with pictures and progress as I go.

Jeremy

TheOtherSide

01-24-2009, 11:45 PM

Get on it... I wanna see...

Jeremy

01-26-2009, 01:46 PM

Pics from Saturday.

Rusty trail damaged stocker.
http://pwned.my604.ca/Rear%20bumper./IMGP1725.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1727.JPG

Always check your nuts and bolts, this could have made a very very bad day!
http://pwned.my604.ca/Rear%20bumper./IMGP1729.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1730.JPG

Bumper off (gotta love a 33x9.5 spare HEHE)
http://pwned.my604.ca/Rear%20bumper./IMGP1732.JPG

Frame, here you get an idea of what I'm working with.
http://pwned.my604.ca/Rear%20bumper./IMGP1733.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1734.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1735.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1736.JPG

More to come soon I hope!

Jeremy

Jeremy

01-26-2009, 10:03 PM

I have found what I think is the best general set up for a tire carer and swing out. It has a double sheer pivot (mine will be beefier) and a nice clean design for the latch. I have found all the parts on Iron Pig Off Road to do this.

To adapt a style like this to the back of my 4runner will require a few changes but this gives you the general idea. Mainly going to use the pivot and the latch design.

http://www.shrockworks.com/Jeep-JK-Tire-Carrier-Rear-Bumper-pr-16222.html

Jeremy

Jeremy

01-27-2009, 11:47 PM

Went to Metal Mart today to get some metal for testing. I am working on a frame bracket right now.

I ended up getting a free pice of 4" x 4" x 1/4" angle iron. It looks like it will work coming off the bottom of the frame and pointing down.

Not sure is 1/4 is good for this or not?

Jeremy

Sero

01-28-2009, 09:34 AM

Jeremy

01-28-2009, 09:47 AM

I think 1/4 would be fine, will that fit inside your frame? I'm not sure how you plan to incorperate it into the frame.

I will need to take some picturs of the the test pice in place were I think it will work. Basicly I'm going to have the L plate welded to the bottom of the frame with the L part facing down kind of beside the shacke on the out side of the frame. It will not go onside the fram like I thought on Saturday Steve if I do it this way.

Jeremy

Jeremy

01-28-2009, 10:46 AM

Looking at some bumper deigns I think I am going to make the side pices out of a single 3/16th plate bent to the contour of the sides. Then just plate it all in so it looks clean.

Jeremy

01-28-2009, 06:51 PM

Found a neat program today Google Sketchup7 works great and is fairly easy to use. There are a few things I was not able to do, just do not know the software.

http://pwned.my604.ca/Rear%20bumper./Bumper%20%231.JPG
http://pwned.my604.ca/Rear%20bumper./Hinge.JPG
http://pwned.my604.ca/Rear%20bumper./Latch.JPG

Did that in about 3 hours, most of that time was trying to figure out how to do things.
:headspin:

TheOtherSide

01-28-2009, 07:33 PM

Jeremy

01-28-2009, 07:48 PM

Very nice.

I like how you have the sleeve for where the swing-out fastens to the bumper.... nice idea for a simple wing-nut style bolt.

I'd triangulate the tire upright a bit more for a bit more stability.... just my thoughts. Otherwise looks very nice!

Yeah I'm working on it, having problems making it look right.

Give me a couple days to get it measure up and then redone.

TheOtherSide

01-28-2009, 07:55 PM

Okay.... fine, you have a couple of days only!

:headspin:

Jeremy

01-28-2009, 08:31 PM

Okay.... fine, you have a couple of days only!

:headspin:

Done!!!!

http://pwned.my604.ca/Rear%20bumper./brace.JPG

:poke:

TheOtherSide

01-28-2009, 08:32 PM

That's what I'm talkin' about.... nice!!

Sero

01-28-2009, 08:58 PM

Cool, I like the design Jeremy.
I tried that google program a little while ago, didn't get far with it.

Jeremy

01-29-2009, 01:18 AM

Cool, I like the design Jeremy.
I tried that google program a little while ago, didn't get far with it.

Its really very cool once you get the hang of it and do a few of the tutorials.

I did that bumper on my first time using it.

I'm going to try and make a front bumper with it tomorrow.

Jeremy

Jeremy

01-31-2009, 03:28 PM

Well this is my idea for mounting the rear bumper to the frame. I want to keep the bumper removable but still very solid when bolted on.

http://pwned.my604.ca/Rear%20bumper./Frame.JPG
http://pwned.my604.ca/Rear%20bumper./Frame1.0.JPG

So in these pictures you can see my frame and shackle mount. I will have about 2" from the shackle to the bracket, I cant the the shackles moving laterally that much when flexed. The bracket will be going to the outside of the frame to keep room for the spare and Aux fuel tank in the future. From this bracket the bumper will bolt on with 4 x 1/2in Grade 8 bolts.

The L part of the bracket from the frame is 1/4in steel and the part from the bumper that bolts to it will be 1/4 as well.

Let me know what you think.

Sero

01-31-2009, 04:39 PM

My biggest concern would be any side to side movement of the peice with the holes in it. Keeping the mounting points on the bumper rigid will keep it from flexing.

Just my thought.

BigWhiteFord

02-01-2009, 10:30 AM

Looks great on paper, I can't see any faults. 6 gr8 bolts should provide enough shear resistance.

Do you plan on having any recovery points on the bumper, or is it strictly to hold the spare tire?

Jeremy

02-01-2009, 06:44 PM

My biggest concern would be any side to side movement of the peice with the holes in it. Keeping the mounting points on the bumper rigid will keep it from flexing.

Well I'm hoping that tabs up the side of the frame will give it enough support.

I may put a couple on the inside as well.

The 1/4 plate that goes to the bumper will have reinforcement from side to side movement as well.

Thanks for the ideas and suggestions.

Looks great on paper, I can't see any faults. 6 gr8 bolts should provide enough shear resistance.

Do you plan on having any recovery points on the bumper, or is it strictly to hold the spare tire?

I'm planing to have two 3/4 clevis mounts and a 2" hitch receiver. The tire carier is a bonus.

Sero

02-01-2009, 07:13 PM

Well I'm hoping that tabs up the side of the frame will give it enough support.

I may put a couple on the inside as well.

The 1/4 plate that goes to the bumper will have reinforcement from side to side movement as well.

Thanks for the ideas and suggestions.

I'm planing to have two 3/4 clevis mounts and a 2" hitch receiver. The tire carier is a bonus.

It's not so much the horizontal plate I would be concerned about, more so the vertical piece's, they don't have much support from side to side especially since the bumper is going to be about 4 or so inche's below those plates (or maybe I'm wong on this, do the plates hang a fair bit lower than I think?), putting some good leverage on them. A few good tugs with side force may start bending things, even worse metal fatigue and cracking.

That being said I think what you have here is about all you can do for mounting...

Jeremy

02-01-2009, 08:59 PM

Ok so I have included what I envision the part from the bumper to the bracket will be. This is all made out of 1/4 plate and I think with the guests and Grade 8 hardware I will have no problems.

The hitch I had on the truck before and that got heavily abused and used by rocks did not have any problems and it was made in much the same fashion that I have made this one with.

http://pwned.my604.ca/Rear%20bumper./Frame1.3.JPG
http://pwned.my604.ca/Rear%20bumper./Frame%201.2.JPG

I have come up with one other idea that I'm looking at but am not sure how its going to turn out.

Sero

02-02-2009, 04:56 PM

That's not much downhang...looks good.

Jeremy

02-09-2009, 01:41 PM

Stalled...............

TheOtherSide

02-09-2009, 04:22 PM

Stalled...............

Meaning...?

Jeremy

02-09-2009, 04:24 PM

Meaning...?

I let the clutch out to fast........

I have been to busy trying to get the Supra going to work any more on the truck. :( Have not even looked at it in a few days, no time and distracted by problems with the Supra.

Jeremy

Jeremy

03-18-2009, 09:48 AM

OK I'm back under way, I have the frame mounts clamped under my truck and it looks like there going to work awesome!

I need to pull them off now and do all the finish work and drill holes gusset......

Hope to have most of that done tonight if I can. Need to get a bunch of Gr8 1/2in hardwear for the braket to bumper mounting, thinking 3-4 per side should be good.

Pics will be up tonight or tomorrow.

Jeremy

TheOtherSide

03-18-2009, 11:16 AM

Nice... saw some clamps hanging under the back of your truck yesterday when I swung by Steve's place.

Jeremy

03-24-2009, 09:20 AM

Last Saturday I was able to spend most the day working on the rear bumper. I got all the mounting brakets clamped into place. The frame braket and bumper braket I tacked together when I had them in there final spot and then took them off the frame. I was then able to drill the 1/2 holes for the Grage 8 bolts with them tacked together. I have will have 4 grade 8 bolts per braket holding the bumper on.

Next task is mesuring up the cross beam and getting that all trimmed and under way. So far I'm very happy how its comming together. Its looking like total over kill but should be nice and strong.

Jeremy:headspin:

Sero

03-24-2009, 09:28 AM

:needpics:

:poke:

Jeremy

03-24-2009, 09:47 AM

:needpics:

:poke:

haha yeah, I got on a roll and did not take any pictures. Doing it by yourself seems to make pictures a non priority.

Jeremy

03-24-2009, 02:16 PM

TheOtherSide

03-24-2009, 02:24 PM

I picked up two tow hooks from Princess Auto, there not the cheap and maybe week power fist ones. Best part was they were only $4 each :D

I'm going to put these on the front of my truck on each of the front leaf mounts. Should be good for now till I get the front bumper built.

I have 3 hooks collecting dust in my Jeep parts bin... same as what you likely just picked up... and they're black!!!! But if you wanna go expensive... stay with your PA stuff...

:D

Jeremy

03-27-2009, 09:30 AM

Kelly, if you are not using them I will take them.

Last night I went to my friends shop to do some more work on the frame brackets. I was able to get all the trimming done that was needed and guests burned on. It was so nice to use a properly working welder. All my welds were perfect, I had Randy look at them and he said there as good as there going to get with a Mig :party:

So now I need to get them back on the frame of the truck and make sure I have not missed anything. Then tac them on and take the truck into his shop for final welding on the frame.

Once I have that done I can then start working on the bumper its self. I have a plan for the swing out and think it will be strong and look nice and clean too.

:welder:

AxelR

03-27-2009, 06:08 PM

pics?

TheOtherSide

03-27-2009, 06:24 PM

Kelly, if you are not using them I will take them.

They're yours!

Jeremy

03-27-2009, 06:32 PM

pics?

Yeah I'm awefull at taking pictures of my projects.

They're yours!

Thanks!

Jeremy

03-30-2009, 08:20 PM

http://pwned.my604.ca/ARB%20&%20M8000/IMGP1768.JPG
http://pwned.my604.ca/ARB%20&%20M8000/IMGP1767.JPG
http://pwned.my604.ca/ARB%20&%20M8000/IMGP1766.JPG

:welder:

Sero

03-30-2009, 08:29 PM

Very nice!!

Jeremy

03-30-2009, 10:22 PM

Very nice!!

Thanks getting there, need this rain to stop so I can get this thing done!

Jeremy

03-31-2009, 01:00 PM

OK the rain is finally stopped and its sunny today so I am going ot try and get the frame pisses tacked on. Once that is done then I will be able to mount the bumper horns and start making the rear cross bar. I'm taking the truck into Randys shop to get his the final welding to the frame. I will do the rest of the welding I think. By tomorrow night I want to at least have the main structure of the bumper done.

From there its just the hitch receiver, shackle mounts, side wings and tire swing out. :headspin:

Sero

03-31-2009, 02:18 PM

Jeremy

03-31-2009, 02:22 PM

Something to think about is tacking some mounting hardware. A while ago I told a friend who at the time bought a truck that had a nice bumper and winch on it to do that so it doesn't get stolen. A week later he called me up and asked me if he could have his bumper and winch back....:(

Yes mine is getting tacked on, even were the Bumper bolts to the frame is getting a couple tacks.

The ARB on the front will be tacked on as well.

Just enough to make it hard to take the bumper off with out a zip disc.

Steve any chance I can use the plasma to cut up this ARB to fit my truck?

:party:

Sero

03-31-2009, 02:28 PM

Yes mine is getting tacked on, even were the Bumper bolts to the frame is getting a couple tacks.

The ARB on the front will be tacked on as well.

Just enough to make it hard to take the bumper off with out a zip disc.

Steve any chance I can use the plasma to cut up this ARB to fit my truck?

:party:

No problem...when aree you wanting to use it?

Jeremy

03-31-2009, 02:30 PM

No problem...when aree you wanting to use it?

This weekend if possible, going to try and get it installed this weekend.

Jeremy

03-31-2009, 10:43 PM

Got some more work done tonight. The weather finally was dry so it was time to get caking.

The goal tonight was to get the frame mounts tacked on the frame and then get the main rear beam all measured out and a good idea how its going to look.

http://pwned.my604.ca/Rear%20bumper./IMGP1781.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1782.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1783.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1783.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1776.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1777.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1778.JPG

Tomorrow I'm taking it to Randy's shop and he is going to do the finish weld on my frame brackets. I'm also going to get the bumper cross bar all cut and placed. I will also be cutting down the horns off the frame and incorporate the clevis mounts.

Saturday I'm going to get Steve's Plasma cutter and cut the hole for the Hitch receiver. I'm also going to cut up the ARB to make it fit with my solid axle swap (I will shed a tear lol).

:welder:

Jeremy

04-01-2009, 12:46 AM

Played around with sketchup a bit more tonight. I was able to use the measurements that I have take off my truck and use it to make what I wanted it to look like.

This gives you a general idea what I'm going for.

http://pwned.my604.ca/Rear%20bumper./dreal%20rear2.JPG
http://pwned.my604.ca/Rear%20bumper./Real%20rear.JPG

:headspin::welder::cheers:

AxelR

04-01-2009, 09:41 AM

Looks good. Might want to cap those side pieces somehow. I can see that becoming a great trap for mud and crap.

Jeremy

04-01-2009, 09:47 AM

Looks good. Might want to cap those side pieces somehow. I can see that becoming a great trap for mud and crap.

Yeah they will be, I was not able to make it work in Sketchup but they will have some sort of cap on hte end. There still going to fill up with crap though. May put a drain hole at the back so that its easy to clean out.

Sero

04-01-2009, 10:00 AM

Looks nice, I especially like how the side piece's form to the bumper/body.

I agree about them being trap, how about leaving them open and using a brace for support? You can strengthen the bottom edge of the 45* piece for sliding.

Jeremy

04-01-2009, 10:19 AM

Yeah that's an idea, I was going to try and tie it into the 4x4 L stock that is coming off of the frame brackets.

I'm a bit worried looking at it that when flexing the back the rear spring shackles may move on such an angle that they contact or jam against the bumper brackets. I have an inch of clearance and the shackle would have to lay back about 3" to make contact.

Any one know how much shackles move from side to side when flexing?

You can get an idea in this pic what I'm talking about.

http://pwned.my604.ca/Rear%20bumper./IMGP1777.JPG

BigWhiteFord

04-01-2009, 10:44 AM

Jeremy

04-01-2009, 01:00 PM

Any provision for mud flaps? :cool: I got tagged in a road check yesterday and warned about not having mud flaps on my truck. Luckily they didn't notice my uncovered spot lights on the front of my truck. Really need to find some covers for those. Anyone know where to get covers for 6" lights?

Bumper looks great Jeremy. Really love that ARB bumper too, I always wanted one of those.

Yes I will be running legal mud flap's all round with quick disconnects for the trail. I got nailed last year for my mudflaps being to small.

For the light covers I would try Prinsess auto for cheap ones. Of not there I know for sure Sport Trucks have the KC ones, no idea on a cost though.

Thanks for the comments on the bumpers, I have wanted an ARB for the front of my truck since I was a kid. Use to watch the Camel Trophy (before it became lame) and always wanted a 4x4 with all the bumpers and stuff lol.

Jeremy

04-01-2009, 11:59 PM

Well tonight I took the truck to Randy's shop to work on our bumpers. He is making one for his 4runner too.

He was able to get some nice welds laid down and it looks awesome. I have also got all the bumper arms done and the cross bar (main bumper) is notched and ready to be welded to the arms. Friday I will get the beam welded to the arms and then start looking at fitting the hitch receiver and clevis mounts.

I for got my camera at home so no pics tonight :(

Driving my truck for the first time in 5 months was quite a experience :eek:

becauseican

04-03-2009, 12:54 PM

Well I finally got around to signing up here. This is Randy with the 96 4runner. Anyways been helping Jeremy work on his bumper as well as building one for my truck, I should post some pics of it to, it is similar to jeremy's.

Jeremy

04-03-2009, 01:19 PM

becauseican

04-03-2009, 02:03 PM

How can mine be a copy of yours when mine is 75% done and yours is some brackets and a chunk of square tubing????, I have my main beam done and one side....

JK, get er done!!

Jeremy

04-03-2009, 02:12 PM

How can mine be a copy of yours when mine is 75% done and yours is some brackets and a chunk of square tubing????, I have my main beam done and one side....

JK, get er done!!

You were reading my mind :welder::headspin:

TheOtherSide

04-03-2009, 08:09 PM

Drove past your place tonight.... hmm... nobody was working on the 'runner. Sad...

Jeremy

04-03-2009, 08:13 PM

Drove past your place tonight.... hmm... nobody was working on the 'runner. Sad...

I was getting my A/C.....working on runner in 5 min.

:mj:

TheOtherSide

04-03-2009, 08:19 PM

I was getting my A/C.....working on runner in 5 min.

:mj:

Chillin' on the couch in 5 min... my day is done!

becauseican

04-05-2009, 09:30 PM

Where is the update pics?, how about with the ARB front?. I hope to have my bumper finished on tuesday/ wed. The paint will still be drying on the drive to the ferry.

Jeremy

04-05-2009, 10:31 PM

Where is the update pics?, how about with the ARB front?. I hope to have my bumper finished on tuesday/ wed. The paint will still be drying on the drive to the ferry.

No time for pictures today, I was going full speed all day. I think Kelly got a couple.

Jeremy

04-06-2009, 08:57 PM

Some poor pictures of the rear bumper on in time for some testing this weekend. I did not get the hitch reciver installed so if I need to get or give a tug it will be wrapped around the support and bumper.

http://pwned.my604.ca/Rear%20bumper./IMGP1791.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1790.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1789.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1788.JPG
http://pwned.my604.ca/Rear%20bumper./IMGP1787.JPG

:headspin:

AxelR

04-06-2009, 09:24 PM

That should hold up a little better than stock.:cheers::vnice: When did you get the big crease in your tailgate?

Jeremy

04-06-2009, 09:31 PM

Its been there longer than I have had the truck, when I do the fender repair I may fix it up a bit.

AxelR

04-06-2009, 09:34 PM

Apparently I have a poor grasp of the obvious.

Jeremy

04-06-2009, 09:43 PM

Apparently I have a poor grasp of the obvious.

It looks a lot worse in the pictures as it is in person.

myles.artus

04-07-2009, 04:53 AM

i think that bumper looks awsome! nice job... i think maybe next year ill try and fab something up for mine...

Jeremy

04-07-2009, 01:12 PM

i think that bumper looks awsome! nice job... i think maybe next year ill try and fab something up for mine...

Thanks, its just the start of the bumper I hope to have it looks much much better in a few weeks. For now it will do the job, the hard part was figuring out the mounting with the rear leaf swap.

:welder:

Sero

04-26-2009, 04:57 PM

Came across this...

http://www.naxja.org/forum/showpost.php?p=244328046&postcount=4

Looks pretty good to me.

Jeremy

08-31-2009, 05:40 PM

Looking at finishing up my rear bumper in the next month or two and came across this idea.

http://www.youtube.com/watch?v=uem6_tw8pKQ

What do you think? Looking like it would work for me. One nice thing with it is the fact that moves up and out of the way and you do not have a large radius swing out to the back.

Let me know what you all think.

Jeremy:welder:

ChrisR

08-31-2009, 05:52 PM

Jeremy

08-31-2009, 05:56 PM

I like it! Nice cause it doesn't get in the way and it wont have a tendencie to wanna close back up on you I think. Only thing is, this looks convienent if you only have a tire on it. If you had a gas can and Hilift or anything else on it. I would suspect it would be to heavy to lift or you would have gas all over the place :)
But I like the idea.

Ah good point! I did not think about that. I want to have the spare, shovel, axe, Hi lift (If I get one) and fuel + one 5lb propane bottle. For fuel I am still looking at adding a 2nd gas tank to the stock spare tire location I dislike Jerry cans.

Trevinator

03-08-2010, 12:27 AM

The best latches I have found are made by "De staco" :welder:

http://www.destaco.com/products.asp?loc=USA&lang=ENG&products=Clamps&Category_1=Pull+Action+Latch+Clamps&Category_2=Standard+Vertical+U-hook

Check it out and then look for a distributor near you! I have used the 334 on quite a few carriers....they are awesome and hold really well! For around $40cnd you can't go wrong!

http://i57.photobucket.com/albums/g235/trevinator72/Truck%20Pics/swingoutmounted4.jpg

Jeremy

03-08-2010, 10:05 AM

The best latches I have found are made by "De staco" :welder:

http://www.destaco.com/products.asp?loc=USA&lang=ENG&products=Clamps&Category_1=Pull+Action+Latch+Clamps&Category_2=Standard+Vertical+U-hook

Check it out and then look for a distributor near you! I have used the 334 on quite a few carriers....they are awesome and hold really well! For around $40cnd you can't go wrong!

Thanks for the link! I had looked at those but am leaning more towards a large bolt with a handle. I still may go that what though, would be much easier to open.

:welder:

Jeremy

03-08-2010, 11:22 AM

Sorry did not update this when I last posted. I have got all the parts needed for the swing out other than a 1" x 5" bolt. I also need to sort out the latch as well. I also got a plate holder and light set up off the back of a 4runner with the factory tire caryer so that will look OEM.

I have been focusing on the other parts of the truck that are more critical to getting it going. But I am now almost done that and ready to get this bumper finished.

The first things I need to tackle are the side wings and there shape and design. The bumper is going to look a bit different than in the schechup picture a few pages back. mainly to save some cost of custom metal bending and materials.

:canadian::welder: