Tacoma bumper build

Thought I'd start with this pic so the next ones will be more understandable.

 

After cutting off the horn ends, I needed to extend the frame. Welded on some 2 x 3 box tube.

 

Welded some 1/4" plate to the box tube. There will be a sister plate that the bumper itself is welded to. The 4 bolt holes allow me to insert washers between the plates to ensure the bumper is orientated the way I like.

 

Box tube welded to the outside plate. Bottom is cut off at an angle. Didn't really need to do that, but was trying to save weight where I could. I had no idea how heavy this thing would end up.

 

cut out some 10 gauge to the rough size of the top of the bumper and welded it to the bumper upright supports.

 

I was an idiot at this time. I did not have any pics of the cardboard mock up. I did save time by only mocking up half the bumper. It made no sense to me to make an entire bumper out of cardboard.

All the pieces on the right side of the truck would be the same as the left. All you have to do is flip them over.

 

Plasma cutter and a straight edge saves huge amount of time and grinding. With a new tip, the cut is almost as clean as a shear.

 

Bending the "wing" pieces to fit the top of the bumper with plain, old bar clamps.

 

Starting to look like the ARB bumper that I had been dreaming about for close to 15 years.

 

hell yeah sub'd!

 

Main parts welded in. Pretty happy so far.

 

Got the bottom angle back piece welded in. Honestly, at this point it goes very fast because I had all the pieces cut out ahead of time.

 

I forgot to mention. The cardboard piece bolted to the truck it a gauge to ensure that the top of the bumper stays level. I can see at an instant if the bumper is tilting forward or backwards.

 

Air dam, valence? I dunno what you want to call them The real ARB's have these pieces, so I welded them in.

 

Jumping ahead with this pic so as to make it easier for the next few to make better sense.

 

Hoops, tube support frame. I drill holes and run the P. cutter up to the holes. No one can make a decent cut freehand with a plasma cutter. Straight edges are your friends.

 

Hoop supports tacked in along with the hoop tubes.

 

Backing up a bit. I don't have a pipe bender. I cheated and had my local muffler shop bend my hoops to the dimensions I wanted. I took some coat hanger wire and bent them to the exact shape I wanted.

The tech was happy that I had no issue with 3 different pieces. They are seamed at the hoop support junctions.

It cost me $20 and a 12 pack of Coors Lite for the pipe and bending. By the way, the tube is just plain old exhaust pipe.

The shit withstood a glancing blow to a deer collision a couple weeks back. Zero damage or deformation to the bumper or the hoops.

 

Tubes welded in and the hoop support band iron welded in. No one can see that the hoop is actually 3 different pieces.

 

1st test fit on the truck. At this point I'm very pleased with the results.