Front bumper build (slow)

Hey there fellow TW'ers! I've slowly been working on putting a front plate bumper together for myself (among other things...) and it's finally starting! So I got the idea almost a year ago when I saw a thread on here that disappeared, then I saw CBI's bumper. I knew I had to do this so I went on the hunt for some metal.

In the meantime I mocked up a cardboard bumper and got everything the way I wanted on the truck. (Heavily influenced on the CBI bumper design)





I have a friend who has an awesome metal shop he uses for sculpture, working on cars, custom work for houses or anything really, that said I could use the space to work on the truck. Still no metal up to that point, but as luck would have it I was working on a job site this past summer and the designer designed a stove that didn't pass code so he had a 7'x2 1/2'x20" 3/16 plate steel box that was going into the dumpster. I grabbed it, then it sat in my yard for a while, and I got it to my friends shop not too long ago, and it's been cut up and ready to CNC.





At this point I just need to finalize the cad work, and then this Tuesday I'm going to start chopping out the pieces, and hopefully if all goes smoothly I'll begin welding it that day.

Disclaimer: this may take a while if stuff hits the fan. I have a pretty full schedule in school and flying which means i can only really work on Tuesdays and Thursdays because he closes his shop most weekends. However! I am optimistic this will get done in a timely manner.

I'm pumped, and as some local members know I've been talking about this for a while now, but I've been afraid to start the thread until I knew I could actually get the work done. I'm confident I can! So I hope I don't disappoint!

Also a shutout to member TRD 09, he's had some helpful tips about his build that he very graciously offered to me. Also to DTFtacoma for his pointer in sketchup. This is why TW rules, too many nice people too willing to lend a hand!

 

I have never designed or made any kind of armor before. I started toying with a rear for my 06. But my friend saw that and asked me to design a front one for his 98. I tried to take some measurements from the front and it was harder than I thought. I then drew up a design based off the weird measurements into a 3D model on google sketchup. I then laid all the pieces flat and cut them on a plasmacam system. Then we tacked it all together and marked everything I measured wrong and had to change. After what seemed like forever we finally got it right and welded it up. Then he had a friend of his paint it.



That is the design he wanted. Flat across the top, no more extra pieces to match the body, no holes for lights or anything. I think it came out great for the first time ever. Seeing your cardboard template makes me want to build one for my rig finally.

EDIT: There are three holes on the skid plate piece that you can't see. I did that for some air to get in and cause I saw it on every other bumper and thought it needed it.

 

Subd

 

Good work man, I'm always here to help, slow and steady...

 

I like that look man! Nice job!

don't want to bugger this up!

 

so quick update, plans fell through to use the cnc cutter. some sort of problem squaring the guide track, so if it's working by this thursday i should have all the pieces cut out.

here's something i was thinking about, i have enough 3/16" plate steel to make the bumper and the winch plate that mounts to the frame similar to cbi's method. the question is should i use what i have, or get the 1/4" plate steel for the back plate winch mount?

i know the 3/16" will be plenty strong... but i wanted to have some leftover to fabricate a rear bumper for my fathers 2000 tundra which rotted out (damn salt).

when i get around to it i'll post up the drawings i've done in sketchup.

 

I have no experience in building shit like this. But all of the bumpers with winch plates seem to boast a 1/4" winch plate. It's probably a good idea.

 

yeah that's what i was thinking. TRD 09 you did your winch plate in 3/16" right? is that holding up well?

 

3/16 with lots of gussets, it's been used a lot and no issues so far

 

I have some decent sized gussets on it, but I'm going to get a price on a 1/4" plate right now. Thanks!

 

Went to the steel shop and all they had (cut offs) was a 20"x40" 5/16 piece of plate steel. However it's only 50 buck which is how much I happen to have. This will be a beefy backing/winch plate, I'll make up for the added weight by cutting some holes in the 3/16" bumper on some of the triangular facets, and front. That will also help with airflow.

Whadya'll think? 5/16" a little overkill? At least this way I'll have plenty left over for making my dad a bumper for his truck!

 

Got around to cutting out the winch plate today! Came out perfect! Sadly once I got there I realized I fudged something on the bumper drawing so I have to tweak one small thing. I'll be headed back to the shop within the next couple of weeks to cut out the rest of the pieces. Here are some pictures to keep people interested!






Forgot I had this... I'll get a lens cover so I don't destroy the camera, but for now... http://youtu.be/otqrw2iB4KY

 

looking good

 

Thinking about activating the inside parking lights on my 08 Taco, looking for some instructional help.

 

That looks great

 

looking awesome cam. Don't throw away those plans!

 

looking good

 

Looks good bud.