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Aluminum plate bumper

Discussion in '1st Gen. Tacomas (1995-2004)' started by Just_Tombo, Apr 21, 2021.

  1. Apr 21, 2021 at 7:18 AM
    #1
    Just_Tombo

    Just_Tombo [OP] Well-Known Member

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    Hey everyone!

    Just got a new to me 2003 Tacoma TRD prerunner to replace my 96 5 lug and wanting to replace the front bumper with something that can support a "just in case" winch for very infrequent off-road (mostly this is a work truck, daily driver, and two wheel dirt toy hauler), so I'm unwilling to pay the weight penalty on a steel behemoth. What I'd like is to fabricate my own aluminum bumper, and I'm hoping someone has CAD files they would be willing to share/trade/sell. I've seen that coastal off road in BC sells a kit, but after shipping and material upcharge, the price is steep, and unfortunately I have no plans to go to Canada anytime soon. Cbi used to offer aluminum but no longer. I checked in with relentless fab in Reno to see if they might be willing to either have aluminum parts cut at a more reasonable price or sell me CAD files for their steel bumper, which I could adapt for aluminum.

    I'm a welder Fabricator by trade, so aside from saving money, I will be able to put that care and detail into the project that no fab shop trying to earn a living should. Appreciate any help you can offer!
     
  2. Apr 21, 2021 at 7:32 AM
    #2
    Wyoming09

    Wyoming09 Well-Known Member

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    So many new protective coatings for Aluminum these days. may as well draw and cut your own parts

    those 1/4" tolerances do tend to add up.

    It does happen .

    Good luck.
     
  3. Apr 21, 2021 at 7:48 AM
    #3
    Just_Tombo

    Just_Tombo [OP] Well-Known Member

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    Just thought that I understand, are you suggesting that no steel bumper design is going to work for aluminum because of up to a quarter inch of protective material? Maybe that's not what you're saying, but In either case it makes no sense to me
     
  4. Apr 21, 2021 at 9:01 AM
    #4
    Wyoming09

    Wyoming09 Well-Known Member

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    You mean to say you have never had to work with a plus or minus tolerance in prints.

    You are so very lucky .

    So never mind everything you work with is 100% correct .

    Good luck
     
  5. Apr 21, 2021 at 9:22 AM
    #5
    jbrandt

    jbrandt Made you look

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    There are some threads around here from folks who made hitch receivers and/or winch mounts that are hidden behind the stock bumper.

    You can either make a hitch receiver mount so you aren't carrying around the weight of a winch all the time when you don't need it, or do the "hidden winch" thing and keep the winch full time.

    https://www.tacomaworld.com/threads/1st-gen-stock-bumper-winch-mount.470522/
     
    Just_Tombo[OP] likes this.
  6. Apr 21, 2021 at 9:26 AM
    #6
    Just_Tombo

    Just_Tombo [OP] Well-Known Member

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    I honestly can't recall ever seeing a tolerance at a quarter of an inch, typically they are in thousandths (5 thou is more typical) if at all in my field, so if you must know, that is why my eyes went cross-eyed with your first response. Furthermore, 1/4" tolerance (per part) on a bumper thats less than 6 feet wide would be insane - are you saying that that is typical tolerance held by these diy bumper kits? I welded up a friend's CBI bumper about 4 years ago and it was almost perfect fit up - couple parts needed an angle ground in to relieve the inside edge to fit up nicer for the tig welded joints, but otherwise, their kit was "perfect enough" for me aside from the weight - so getting that cad file and having aluminum plate cut to the file should yield similar results. But alas, they do not offer the kit anymore and their sales staff has dodged multiple emails so far
     
  7. Apr 21, 2021 at 9:28 AM
    #7
    JKO1998

    JKO1998 Well-Known Member

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  8. Apr 21, 2021 at 9:29 AM
    #8
    Just_Tombo

    Just_Tombo [OP] Well-Known Member

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    Sweet! Thanks for the helpful reply, the hidden winch enticing! Are you talking about a rear receiver mounted winch? Or...
     
  9. Apr 21, 2021 at 9:41 AM
    #9
    jbrandt

    jbrandt Made you look

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    Front hitch. Nice thing about a front hitch and a winch plate is that you can use the winch for front or rear recoveries.

    Something like this:
    https://www.amazon.com/CURT-31010-Hitch-Mounted-Winch-Mount/dp/B001GMX3GE

    There are several commercial options for both (at fairly reasonable prices) or fab up your own.
     
  10. Apr 21, 2021 at 9:55 AM
    #10
    Just_Tombo

    Just_Tombo [OP] Well-Known Member

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    Dude! Thank you. That's awesome. At the end of the day, nothing is lighter and cheaper than staying stock. Right now, this is looking very tempting. Compared to building my own, this is also more likely to be ready for summer time trips
     
    jbrandt[QUOTED] likes this.
  11. May 16, 2021 at 11:25 AM
    #11
    Uncle Leo

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