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C4 FAB '16+ Overland Series front bumper installation instructions

Discussion in 'C4 Fabrication' started by C4 Fabrication, Aug 11, 2016.

  1. Aug 11, 2016 at 7:43 AM
    #1
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Hey Everyone, here are the install instructions for our Overland Series full replacement front bumper.

    Tools required:
    -Philips head screwdriver
    -Flat head screw driver
    -10mm wrench/socket
    -12mm wrench/socket
    -14mm wrench/socket
    -3/8" drive extension for 14mm socket
    -17mm socket
    -1/2" wrench/socket
    -3/4" wrench/socket
    -Tin snips, knife, die grinder, pneumatic reciprocating saw- something suitable for trimming the plastic fender flare.
    -Friend or two to help lift and install bumper

    First the original front bumper needs to be removed.
    Here are some quick and basic instructions for removing the original front bumper.
    1) There are two plastic clips like these on each side at the front of the inner fender area. Pop the plastic clip up, then push the plastic inner fender away from the steel fender.

    upload_2016-8-11_8-24-5.jpg


    2) Remove all of the black and silver screws with 10mm head from the front inner fender area and along the bottom of the bumper.
    DSCN2614.jpg

    DSCN2615.jpg
    DSCN2616.jpg
    3) remove the two screws from the top of where the grille attaches to the inner structure.
    DSCN2617.jpg
    4) Then remove the plastic clips holding the grille.
    DSCN2618.jpg
    5) Now the grille can be removed. Lift slightly and pull forward and the grille will pop loose from the lower clips and come out.
    6) Now remove the remaining plastic clips from the front bumper cover.
    DSCN2619.jpg
    DSCN2620.jpg

    DSCN2621.jpg
    DSCN2623.jpg

    7)Now pull the front of the fender flare away from the bumper cover. These clips should just pop loose as you pull out on the flare.
    DSCN2624.jpg
    8)Now pull down on the bumper cover at the front lower area to expose this orange square clip. Remove this clip so the inner fender plastic can be pulled loose.
    DSCN2625.jpg
    DSCN2627.jpg
    9) The inner fender can now be pulled back.
    DSCN2628.jpg

    10) Now the bumper cover can be removed from the truck. Pull the front edge of the fender flare back and then pull down on the bumper cover plastic to remove it from this round plastic tab on each side.
    DSCN2629.jpg
    11)Then pop the outer corners of the bumper cover away from the headlight area where the bumper cover meets the fender. The bumper cover just snaps into place under the headlight so gently pull out and the cover will come off.
    DSCN2631.jpg
     
  2. Aug 11, 2016 at 7:51 AM
    #2
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    12) Now that the plastic cover is removed, the other components behind it can be removed.
    Use a 14mm wrench or socket to remove the aluminum crash bar.
    DSCN2632.jpg
    Once the nuts are removed, you will have to pry the crash bar forward with a small pry bar to get it to slide off of the mounting studs.

    13)Remove the frame rail end caps and tow hook using the 17mm socket or wrench.
    DSCN2633.jpg
    DSCN2634.jpg

    14) Now the plastic clips on the front edge of the fender need to be removed.
    Pull the fender flare out away from the fender to expose this red clip on the backside of the fender. Pop the clip out.
    Then remove the screw from the outside of the plastic bracket with the 10mm socket. the plastic bracket should now come off the fender.

    DSCN2653.jpg
    DSCN2655.jpg
    DSCN2657.jpg
    DSCN2659.jpg
     
  3. Aug 11, 2016 at 8:09 AM
    #3
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    15) Now the end of the fender flare needs to be trimmed off at the front edge of the fender. We suggest using a piece of masking tape to mark your cut line on the flare. The flare needs to be cut so that it ends up flush with the edge of where the outer body line of the fender stops. Have a friend hold the flare away from the fender when cutting so that you do not cut into the actual fender or scratch the paint.
    Always wear appropriate safety gear when cutting the flare!
    Here are a couple pictures showing where we made the cut and how it should look completed. This is a pretty simple process so numerous pictures and instructions really aren't necessary.
    DSCN2664.jpg

    DSCN2665.jpg
    After cutting the flare, a box cutter or sharp knife can be used to clean up any rough edges from the cut.
     
  4. Aug 11, 2016 at 8:17 AM
    #4
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    16) Now that the flare is trimmed, the fender area that will be seen between the edge of the new bumper and the edge of the fender can be painted black.
    Scuff up the area and tape off the fender and headlight around the area to be painted. Use a good quality black rattle can paint to paint this area so that it is not so noticeable after the new bumper is installed.

    Passenger side shown in photo:

    front bumper gap spray - c4.jpg

    Driver side after painting fender clearance area and installing bumper:
    front bumper gap spray 2 - c4.jpg

    Now the grille support bracket needs to be installed. This bracket provides a mounting location for the grille now that the plastic bumper cover attachment points are gone.
    This bracket attaches to the two 8mm studs on each side of the inner structure supports and then gets screwed to the grille using the hardware that is already on the truck.
    17) First remove the nuts using a 10mm wrench, and install the bracket onto the studs. Loosely install the nuts to hold the bracket in place. "P" is for passenger side and "D" is for driver side.
    Copy of Front bumper grind 3 - c4.jpg
    18) Then install the screw through the other end of the bracket into the back side of the grille. (Passenger side shown)
    Copy of Front bumper bolt 2 - c4.jpg

    19) The last thing that needs to be done on the vehicle before the bumper can be installed is to relocate the power steering cooler. The cooler needs to be moved back closer to the radiator to provide room for the winch to fit.
    Remove the two bolts holding the cooler to the frame at the front of the vehicle.
    DSCN2639.jpg
    Also remove this 3rd bolt from the passenger side wheel well area that holds the PS line. This bolt needs to be removed to allow the line to move back with the cooler. This bolt does not get re-used and there is also not a relocation bracket for this location. The line will stay in place just fine without it.
    DSCN2641.jpg

    20) Here are the relocation brackets that will be used to move the cooler back. "P" is for passenger side and "D" is for driver side.
    DSCN3736.jpg
    DSCN3735.jpg
    DSCN3734.jpg

    Install the brackets into the original mounting holes for the PS cooler and then attach the PS cooler to the brackets with the supplied 5/16" bolts.
    Here is the passenger side attached:
    DSCN2649.jpg
    DSCN2652.jpg

    And the driver side:
    DSCN2650.jpg
    DSCN2651.jpg
     
    Last edited: Sep 23, 2016
  5. Aug 11, 2016 at 8:32 AM
    #5
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    If you are re-using your original fog lights with this bumper you will be receiving a bracket from us to mount the lights to. Here is how the lights fit into the bracket.
    Use the supplied plastic spacers and cap screws to attach the fog lights to the brackets. The brackets are labeled D and P (driver and passenger side) install the driver side fog light into the "D" bracket and the passenger side fog light into the "P" bracket.
    DSCN3074.jpg
    DSCN3071.jpg
    DSCN3072.jpg
    DSCN3076.jpg
    DSCN3077.jpg
    DSCN3078.jpg
    DSCN3079.jpg

    Now install the brackets with lights into their corresponding side in the bumper. "D" on the driver side of the bumper, "P" on the passenger side.
    The bracket bolts into the bumper in front of the other bracket that is in place for aftermarket lights. If you want to upgrade later on to LED type lights, the original fog light brackets get removed and the new lights bolt into the flat tabs.
    After the bumper is installed, the brackets can be adjusted for proper light output direction.
    DSCN2707.jpg
    DSCN2708.jpg
    DSCN2709.jpg

    DSCN2710.jpg
    DSCN2723.jpg
     
  6. Aug 11, 2016 at 8:47 AM
    #6
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    If you are installing Baja Designs Squadron lights into the bumper, this is how they fit.
    DSCN3621.jpg
    DSCN3622.jpg
    DSCN3623.jpg
    DSCN3625.jpg

    If you are using lens covers of any kind, they will need to be clipped on from the outside after the light is installed into the bumper.
    DSCN3619.jpg
    DSCN3620.jpg

    Here is how the Baja Designs S8 20" lightbar fits if you are also installing one into the bumper.
    DSCN3138.jpg
    DSCN3139.jpg
    This photo with the 20" S8 light installed is of our Lo-Pro winch bumper, but the fitment is the same. This is how your light should look from the front.
    DSCN3056.jpg
     
    Last edited: Aug 11, 2016
  7. Aug 11, 2016 at 9:42 AM
    #7
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    If you are installing a winch into the bumper, that process is pretty self explanatory. The winch bolts directly into the bumper using the bolts supplied with the winch. The bolts can be accessed from the open slots in the back of the bumper and the slotted cutouts in the bottom face of the bumper. This is the winch mounting plate that the winch will attach to:
    DSCN2711.jpg

    The fairlead will attach to the vertical mounting plate in front of the winch mounting plate.
    This photo shows the fairlead mounting plate from the front and the winch bolt access holes in the bottom face of the bumper:
    DSCN2839.jpg
     
  8. Aug 11, 2016 at 9:53 AM
    #8
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
    Apr 30, 2014
    Member:
    #128867
    Messages:
    1,179
    Gender:
    Male
    First Name:
    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Finally the bumper can be lifted up onto the vehicle and bolted into place. We currently do not have any pictures of the actual lifting and mounting process, but that is also pretty straight forward. The bumper will bolt onto the original mounting studs where the aluminum crash bar was located. Also the extra 1/2" x 1 1/2" bolts and washers get installed into the bottom corners of the frame cross member. The extra 1/2" washers sent with the bumper can be used to place behind the bumper mounting surface onto the mounting studs if extra adjustment or shimming of any kind is needed.

    Here are the mounting locations for the front bumper:
    DSCN3128.jpg DSCN3132.jpg DSCN3130.jpg DSCN3129.jpg

    Your front Overland Series bumper installation is now complete! Here are some photos of the bumper powder coated and installed with all of the accessories.

    upload_2016-8-11_10-53-13.jpg

    upload_2016-8-11_10-53-28.jpg
     
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