Bored Clerk's Rear Bumper Build

Yeah , I had that moment in my wood working about 5 years ago , such a difference when you need it , haha

 

TRUTH

 

Today was pretty awesome even with a stupid setback.

I did a bunch of finish welding. Then did this!




Then this!!






Then I opened the swingarm and realized that the tire hits the tail light just a few degrees short of opening 90. Doh! 90 is all I wanted and I missed it by that much! Haha. So, I pulled the tire carrier swing arm off and will take it to work to cut the upright off with the bandsaw. Then I'll move it to the right 1/2" and weld it back on. It'll be a little time consuming but it needs to be done.

Other than that, I'm pumped! It looks great to me. And, yes, it is right up against the tailgate. And, yes, that's fine. I designed this specifically for use without a tailgate as the tailgate will be replaced by drawers and ambulance doors.

More tomorrow!

 

Looking great! Yeah, I had one of those moments when I did mine. Welded a double Jerry box on to the left swing out and liked about 1/2" clearing the corner of my bumper. Haven't fixed it yet since I still get about 105° out of it but it's on my list

 

Looks awesome! Great job man. Home stretch now.

 

Home stretch? Haha, not sure about that. I've definitely turned a big corner if I can get this spare tire placement issue fixed easily tomorrow morning! The side wings should take considerably less thinking and welding, I think.

 

I really only find down cutting blades useful when cutting wood with a thin veneer or a laminate adhered.
I used a normal up-cutting 21 tpi bi-metal blade to cut my bedsides. I learned the tip from a shop that installs automotive sun roofs. I cut a installed a sun roof in my 2001 double cab Tacoma back when it was brand new. Flawless. It's now the only way I cut thin metal for finish carpentry that uses metal (I do commercial construction) and for some metal door hardware applications. If there is paint to protect, at least 3 layers of blue tape is a must. If you don't push (let the blade cut at its own pace) it will not catch at all. You are left with a smooth cut and no heat distortion or paint damage.
Sorry for for the long post. Just want to share what has worked for me. Good luck.

 

Nice work, been watching since the start, can't wait to see it painted and done, great job.

 

Fixed all my mistakes today! And probably made all new ones, haha.



Giant bandsaw to the rescue! Hacked this off nice and clean in about 5 minutes.



All cleaned up and ready to weld.


I finish welded everything I could on this swingarm and mounted it up. There is literally nothing else that I can weld on this thing right now. I'll get more parts this week. Plus I'll design more that need cutting and welding.


Tire opens past 90 degrees now!




And, more pictures of it with a tire. Just because.

I'm still stewing on the placement and where to cut for the side wings. Decision paralysis? Just plain chicken sh*t? Haha probably the latter. I'd rather think a little more than make a bad decision.

I made a big decision today. I've decided to buy a Jerry can carrier and bolt it on. I haven't designed one that I like and I need to move this project along. I'm 90% sure I'm going to buy a CBI dual can holder. It will only carry 2 Scepter MWCs (water cans) so I need to make sure it's compatible. I'm also open to any feedback on Jerry can holders that any of you would suggest.

That's it for today.

 

Just ordered my CBI dual can holder. And a little rotopax for good measure. I got plans...hopefully it all goes together the way it is in my head! I should have made this decision weeks ago...id be done with it already. Oh well, this is a learning moment, I guess?

 

Did my usual lazy Monday thing.


Pulled these off. Now I see why so many people choose to cut the bedsides without removing the flares.


Broke pretty much all of these.


Overall, I like the flare less look but the fender lip looks so unfinished without the flare because of all the mounting tabs and the fender liner. I'll put 'em back on...once I pony up the $$$ for new clips.


That's it. One step closer to cutting off the cleanest part of my truck! Haha. Bath needed...stat!

 

Oh, and my rotopax has shipped and CBI was kind enough to pull one of their dual can holders out of the process so I could get one bare...no powder coat. I may want to modify it. Also, I want all of the powder coat to match.

 

Work has been crazy this week. Tons of jobs hitting all at once with crazy short deadlines. Long days...

This showed up though!


1.75 gallon rotopax with a locking mount. I'm planning on hiding this behind the water cans. We'll see how that goes.

Now, I know what you're thinking. "1.75 gallons!? Why bother?" Usually, you'd be correct in that thinking. However, we have a 34 gallon gas tank under the truck so that's more than two jerry cans worth of fuel already in the tank over and above the factory 21 gallons. I got this small rotopax more as a 'help your fellow traveler' deal. I've come across both cars and motorcycles that have run out of gas just several miles short of the next station. 1.75 gallons is perfect for that. Especially for motorcyclists as they don't even have a safe/dry place to hang out waiting for help.

My CBI dual can carrier is due in tomorrow and my laser cut parts are supposed to be ready tomorrow or Friday...need to check on that.

 

I bought these clips from a supplier, pretty cheap like a buck a piece maybe, I'm trying to find the Web site but drawing a blank. Maybe somebody can chime in. Great looking work on the bumper btw. I really have enjoyed the thread.

 

Thanks for the heads up! A link would be awesome but just knowing they're out there, I'll start searching.

 

https://www.tacomaworld.com/threads/fastenal-fender-flare-clip-part-numbers.116491/

 

Where did you get your 34 gallon fuel tank?

 

Nice job man!

 

That's good info right there. Thanks for the heads up!

 

I got a long range automotive tank from Australia. They aren't listed on their website (at least not when I got mine). It was a pain in the butt to fit because it was originally designed off of a DCSB and the cross members are slightly different on an AC. I had to make three of the five mounts from scratch because what they supplied wasn't even close to working. Knowing what I know now (cost to import, mostly), I would have spent more time talking to CES in Bend, OR about their tank. My only concern with the CES tank is it may just be too big (40+ gallons iirc) to really fit every truck without interference issues and they use the factory strap mounts which may not be sufficient to hold the tank in place properly. At least that was the story when I bought mine.