Just released! Relentless Fab 96-04 Tacoma front plate bumper

Yup same thing with mine. I punched mine out and got it to fit

 

Sure that's no problem at all. I'll throw some in the mail tomorrow.

Thanks for the pics. Edited one of my files now and I'll edit or delete any others with wrong dimensions.

 

Thanks Eric

I sent a PM with my info just incase

 

Hey Eric. I am FINALLY able to get a bench area at the shop cleared off to get this thing started on the DIY kit for my 97. I have the top plate laid down, and the main center piece set in position. I noticed about a 1/8" gap on one side versus the other. I don't know if these pics will show well enough for you to see. Will this be a problem when I weld? I don't want one "wing" to sit higher than the other.

This is the outside on the left (Take into account the bumper in on a bench, upside down) where there is a 1/8" gap between the perpendicular edge of the center upright, and the horizontal "top plate" The gap itself is not on the point, but where the two plates on the center piece meet up, then join with the top plate.




This is the same left side, but from the back side. Same contact area though.




And here is the right (passengers) side, same position. You can see it lines up almost perfect at that position. There is barely a 1/32" gap.




It looks to me as a slight misalignment when the center unit was lined up and welded. I know I can fill it when I weld. I just want to know BEFORE I do anything, if you think this would cause any issues with one side of the bumper being higher than the other. 1/8" at the center being deflected, would that be a bigger gap at the ends? Should I grind down that part of the center support so that it will line up better, or what do you suggest? I am open for whatever. Just want your recommendation.

 

Shave down the vertical plate slightly to allow the top plate to sit flat/flush. That's what we do when they come out slightly tall as yours did; I've kept the dimension of them the same as I would rather shave them slightly during assembly, than have to weld a gap if I shortened them up.

 

Also, to those who had mentioned the side mounts and bottom holes not quite lining up, those have been fixed in my files so thanks for the feedback/measurements everyone.

 

OK, will do! Thanks for the fast reply!

I know I got mine in that same group. Will I need new side mounts? Or was there a fix that I missed?

 

They usually fit, though a bit snug. If necessary, a die grinder can open the holes a little to get them to fit, or if you would prefer(and I don't mind at all obviously!) I can send you a pair of the revised ones so you don't have to mess with them.

 

Yeah I had the same happen when installing mine. Wasn't a big issue to widen them a mm or 2. Glad it's fixed for other buyers. BTW, I love my bumper!

 

No need to waste your money. I will get them drilled out to fit. Thanks!

 

Well we now have a nice monkey wrench in the bumper project. As I had suspected, and as others had told me was most likely the case, my Clark welder is not powerful enough. Even on temp setting of 4 (the highest) I cannot get any penetration into the steel. It simply arcs up and pools on top. So it looks like I will have to buy another welder. This sucks.

 

Try preheating the steel first

 

I really do not think preheating will do any good. If it can't weld at room temperature, then the welder is just simply not strong enough.

 

preheating does allow for more pen, but i dont see any reason not to buy a new welder :] you should get a tig welder!

 

I weld VERY rarely. No reason to shell out the kind of money needed for a TIG.

 

thermal arc 181i... mig/tig/stick combo and only around $800

http://store.cyberweld.com/tharcfa18miw.html

 

ugh.
i was hoping for something around the $500 mark. lol.

 

Look great! Not sure if that hoop is big enough to fit my 9" hid Australia.

 

Well I went ahead and bought my welder. I got a good deal though. It is usually priced around $1000, but I found one on sale, and with a coupon code got it for $800. I bought a Lincoln Power Mig 180C. From what I saw the "C" model uses a cast aluminum wire feeding mechanism instead of plastic. This is the kit I got:

 

Congrats on the new welder.
Just curious, why not the extra $70 and spring for the multi process thermal arc?
Digital readouts and many more adjustments for fine tuning, plus the multiprocess capability, rated for the same duty cycle but at higher amperage, has the metal drive roll setup and the same 3 year warranty. Inverter tech makes the thermal arc only 33lbs vs the 80 the lincoln weighs so it's more portable too.
Even includes a mail in rebate for them to send you a free auto dark helmet worth about $125