DIY Aluminum Bumper with Custom Fog Light Castings

I wanted to share the results of my tacoma front bumper project. I wanted to use KC HiLight G34 Fog lights, which are sort of rectangular. Here was my end result.



I started with a DIY Aluminum kit from relentless, then I designed the sockets for the for foglights based on the beam spread from the lights. I designed them with onshape, you should be able to access and download stl files with this link. You will probably have to signup but it's free with certain limitations. If you want me to just send you the stl files I could do that too

https://cad.onshape.com/documents/f...d407e446c5b23d8248/e/edad902bfb434389afe9cfe0



I then 3d printed the parts and built some half sand half plaster of paris moulds. I burnt the plastic 3d prints out of the mould with an old oven on self clean. Then I cast them in aluminum. There is all kinds of resources on how to do "Lost PLA" castings on the internet.



I printed off some stickers with some fiducials for aligning them with a laser level. Then jigsawed out the holes.



Then I welded them in, filled them nicely with body filler/putty and painted them.








All in all it was a pretty fun project. Questions and feedback are appreciated!

 

Looks good OP! Nice work

 

Definitely give the front of your truck a very unique look. Awesome job! I'd be interested to see what the light look like during the night.

 

Here is what the lights look like at night. Not the best pictures but its been raining.

 

Looks like it throws a good amount of light out there! Good job!

 

Well done!! Bumper looks awesome!! What model relentless bumper is that, and how hard was it to put together? Reason being is I was looking to do one myself.

 

It is the aluminum "summit" http://www.relentlessfabrication.co...products/2012-2015-tacoma-summit-front-bumper , I don't know if he does aluminum DIY kits anymore.

It wasn't an easy job, the instructions were limited and my seams required an obnoxious amount of finishing before I was happy with them. You also sort of freeform tack it together while the base is attached to the truck. You have to let the aluminum cool as you weld the seams so it took like 2 days for me to finish it.

 

Awesome!! I the Eric @RelentlessFab are still producing DIY bumpers. Did you use spool gun or Tig?

 

I used a spool gun on most of it, tig on the tubes and the anchor points so they looked prettier.

 

Awesome job!