Flatland Winch Bumper on 1998 Pre-Runner Install

I am installing a Flatland 4X4 winch mount bumper on my 1998 Pre-Runner. I did a write up on a similar installation on my 1996 4X4 a while back and figured Id follow up with this. There are differences in the frames between the 2 years. The 96 has a metal square spacer to space the bumper forward some 1 1/2 or 2 inches and is easily removed. With the 1998 the frame is just longer and this presents a problem. The Flatland bumper projected out too far and was just ugly sticking out that far. When I spoke with Flatland about this they recommended taking the captured nut plate off the end of the frame and shortening the frame... I am not a fan of one way modifications. I can put her back to stock in a few hours.


Stock Front


Stock Side


Bumper Gone



Modified mount to move bumper back.



cross brace interference. Had to trim apx. 1/4".



Winch trial fit.



Bumper trial fit.




Drivers side fit.





Passenger side fit.

I will be filling the end of rectangular mount with a plate that has a captured nut and welding a tube spacer in the frame at 90 degrees. The bumper mount will be cross bolted and end bolted to the frame.

I am going to install Cadillac Eldorado horns... loud doesnt go far enough for these things. I am deciding if I want to put round, square or rectangular LEDS behind the bumper through slots or not.

I have windowed the top of the bumper enough that I can remove the winch without having to take the bumper off. On my '96 I made it such a pain in the rear to remove the winch ... this truck is one of my Cabo vehicles and I didnt want to make it that easy to steal the winch. I will make a sheet metal Dzus's fastened cover to cover the drum and neutral lever.

To date, costs are $200 for the water-jetting of the plate and the Smittybuilt XRC9600 was $264, on sale a 4 Wheel Parts. I had enough plate from the first bumper to make this one.

I will have to drive her around for a bit to see if I want to put these on her with the stiffer springs. The '96 was a bit too soft until I put them on. I will weight the entire bumper/winch assembly when I am done.

http://www.lowrangeoffroad.com/toyo...h-old-man-emu-springs-2-0-3-0-lift-11299.html

I am going to take the aftermarket headlight housings out and see if I can modify them to allow the turn signal bulb/holder to fit inside of the headlight housing. It looks like it should work.

Not really looking forward to all the MIG welding, grinding, welding, grinding.

Going to look at powder coat colors tues. but probably going to go with basic black.

 

I didn't know you fab as well. Sweet man. Cabo vehicle? As in you're an expat or soon to be?

 

Thanks... probably going to move there in the next 3 years. Dont think I am going to go the citizen route, just a legal resident. I will have to check closely with the authorities, if possible I will order a new Hilux diesel for my day to day. Last time I checked they were $33k ish + 16% IVA + + +

When the 96 was up in CA I used the winch every 2 weeks of so, pulling crap around that would take 2 dudes 1/2 a day. You never know the versatility of a thing until you have it and then it is gone.

i talked my buddy who wants to learn to weld into doing the welding for me... Once the machine is set up a monkey can pull the trigger and wiggle the lead, after all, its just a bumper and a grinder and flap wheel can make it look good.

 

I finally found some time to work on the bumper/winch install and I am 99% complete. I took a bit of time to think about the turn signal modification and I came up with what I think is an acceptable solution

These are the aftermarket headlight that I have.



This is the bottom view



This is the turn bulb housing socket cut off



This is it epoxied to the headlight.



This is modified front view



This is the modified headlight Holder assembly



I did not want to break the housing so I made some access holes to get the the retainer screws.



semi completed... off to the auto parts store for some amber turn signal bulbs...



Amber bulb installed ... Cant up load Videos as far as I know but I can upload zipped video.
One is with headlights on the other with headlights off.

The only issue I have with these assembly's is that there is a slight looseness in them. Is it enough to vibrate the light at night... not that I have noticed. I took some black RTV and affixed the headlight to the housing in a few places.

 

Damn, I was just noticing today my headlamp assembly is starting to yellow again. You happy with the quality on those? They on Amazon?

 

I am prepping to build this bumper for my 2003. I want to put the turn signal into the side marker light housing. Was going to change the blinker pigtail to the same as side marker light but now will look at cutting off the blinker housing and epoxy to side marker (Tried to drill hole & insert blinker light into old side marker housing but bulb/socket is too big either way I’ve tried.) Thanks for the idea.

 

I know it's been a while but how far off the inside of the front does your tubing stand? I made the mistake of building the bumper before the mounting brackets so it's been a challenge figuring out the dimensions.

 

I will crawl under her tomorrow and see if I can measure that for you.