Rust between ARB bumper and fender?

Started seeing some surface rust showing up as you see above. It wipes away during a wash so it’s coming from behind the fender flare somewhere. Tried looking underneath to see if I could find the source but to no avail. Anyone else seen anything like this? Is it likely the mounting hardware?

 

My money is that the fender flare rubbed away the finish on the bumper and the bumper is rusting.

 

my ARB is no where close to the fender like that.

 

you gotta leave a gap for flex, looks like there is none there

 

Readjust the bumper for clearance and get after the rust. Spray it with wd40 or flow some oil in there temporarily soon. The paint has rubbed off the fender (bumper) fender flare is plastic.

 

How much gap should I leave? Had the bumper installed at a shop and don’t have the paperwork anymore.

 

i have about a fingers width

 

This.

Same deal on my truck. Had it readjusted a few years after original install. Then had it adjusted again about five years after that. I didn’t do anything to correct the paint that was worn away. Just cleaned it up to the bare metal in those spots.

 

I have about .25" of space.

 

ARB’s instructions say to leave a 15-20mm gap between the fender flares and top of the bumper. I also had mine installed at a shop and had to bring it back for a readjustment when the flares started rubbing the powder coat off.

 

^^^^ All of this.

I don't have an ARB but I made sure I had a good 1/2" clearance all around the fender flares and grill.

 

That bumper should not even be touching the flare,you need to adjust it so it has at least 1/4 inch opening.

 

When I installed mine, I cut two spacers out of 3/4" plywood to hold the bumper in place while I tighten the bolts. Obviously removed the plywood after. With the weight distribution, it wants to roll closing that gap when it's loose.

Edit: the plywood goes between the bumper and fender...

 

Check front body mounts. Had the same issue with my relentless bumper. With fresh body mounts, problem was solved. I went all energy suspension. https://www.tacomaworld.com/threads/polyurethane-radiator-support-mounts-cab-also.361346/

 

Thanks for all the help guys, pretty sure y’all are absolutely correct. Unfortunately it’ll be a bit before I can correct it, going to sand it down and rattle can it.

 

I've got the same problem with some rubbing, probably my body mounts since the truck is old and wasn't doing it after I installed the bumper. One of these days I'll get around to replacing them, there are new mounts sitting in the garage, but I've been too lazy.

 

I’m getting close to fixing this. Thinking I’m going to sand the whole thing down and repaint the entire thing. Anybody have recommendations for prepping and sanding? What grit sand paper should I use on my rotary?

 

No need to repaint the whole thing unless it's in really bad shape. I would sand down that area and paint with VHT Epoxy Paint. I've used the gloss black variety on my ARB bumper for small touch ups and it matches pretty well. They do make it in satin black as well, but I have not tried it.

 

It’s not that bad, spotty surface rust in limited areas. I wasn’t sure about mixing paint with the factory powder coat. Also what grit sandpaper would you think?

 

Sorry for resurrecting a dead thread but I kinda hit a snag. Started to take the bumper off and didn’t get far. Started by removing the ARB splash guard but it seems the hardware (specifically the “nuts” the screws screw into) have rusted and broke. I can’t seem to access behind the bumper to hold the nut steady and remove the screws holding the splash guard in place. Any recommendations? I tried looking for bumper removal threads/videos but the only ones I’ve found are installation vids.