Show off your DIY armor!

Getting ready to start building a rear bumper modeled after the C4 overland high clearance bumper with a hidden tow receiver behind the license plate (see photo below). I've been playing around in 3D Builder (a 3D printer program that was already on my computer) to sketch up the concept of the skeleton, namely the frame brackets, towing receiver, a 2x4x1/4" tube to connect them, and the recovery points. Below are a couple different perspectives of what I've come up with.


My plan is to cut openings in the 2x4 to run the receiver through it and weld on each side of the 2x4. Similarly, I'll cut openings in the frame brackets and run the 2x4 through them and weld. That seems consistent with what I've seen on how many tow hitches connect to the frame brackets, and seems more solid than just fillet welding to one side. Note the the C4 bumper doesn't use a 2x4, but instead relies on the plate bumper to transfer the load from the receiver to the frame brackets; I feel the 2x4 will be much beefier since I occasionally pull a 4,000 boat/trailer out of the water.

The arrangement below is very conceptual and crude, and I still have to work out the geometry. I may need to go with an 8" wide plate for the frame bracket to lower the 2x4 and receiver so they can line up with the bottom of the license plate. I would appreciate any feedback or suggestions.

 

I keep playing around with the idea of building my own rear bumper. Especially since I may be getting access to a cnc plasma table. Never heard of 3D builder.... Interesting.

 

Buhler? (crickets chirping)

 

looks good to me. Glad to see the clevis mounts attached right to the frame plates. Passing all those parts through each other also sounds like a good plane.

The only thing that comes to mind is bracing the other end of the receiver tube, but I’m assuming that is already in the plans. Will the end of the receiver also go through the face of the bumper?

 

Correct, I plan to angle the other end of the receiver to match the angle of the license plate mount and weld it. It will look similar to the second picture I posted showing the license plate flipped up (also copied below). It's a little hard to see, but if you look closely you can see how they've welded that end of the receiver to the bumper.

 

you are doing the same as what we plan for my bumper, you definitely need the cross tube there if you want to actually use your hitch.

Also, do you have any info anywhere on here on your homemade skid plates? would be interested to see that.



but we worked on the CAD for my rear bumper more yesterday, still need to add recovery points, cutouts for LED pods, and im still not sure if i love the shape of the side fender guards yet

 

I made the skid plates mostly on the fly. I did use cardboard where the mid skid meets the TRD front skid that came with the truck in order for them to mate up properly. I bought a piece of 2'x4' 3/16" plate steel to make the mid and rear skids, so that set the width of each skid (2') and I cut them to length as needed for mounting. On the tranny skid the reinforcement was arranged to not interfere with the URD Y pipe I installed, which essentially reroutes the exhaust pipe from behind the transfer case to under the transmission. For the rear skid, I ran some 1-1/2" square tube from the back of the rear skid to connect to my Mobtown rock sliders.

Edit: I'm liking the way your bumper is coming together. I know what you're saying about the sides but not sure what I would do different. Maybe add a tube on the top of it or something like that. I'd be interested to see how your recovery points, receiver and frame brackets are all tied together.

 

I wished I had fabrication skills like you guys have! I would really like to build a rear bumper that has integrated steps in the corners GM does on theirs. About the only then GM does right. haha

 

Well, I don't have the fabrication skills yet, but hoping to develop some through this process lol. So far I've only made skid plates and added railings to my utility trailer, but this bumper should be a bit more challenging. I'm going to try and incorporate the integrated steps into my build like you mentioned. I have the Toyota flip down step that I ordered as an accessory, but that will be another casualty of the rear bumper (along with the BSM sensors), but having an integrated step should work just as well for me.

 

I found that the BSM were pretty useless, that’s me though. I actually tore one off out wheeling one day...switched the button off and haven’t looked back since.

 

I’m pretty sure that country song “Jesus take the wheel” was playing in my head while cutting this bumper off.

 

@Mojo Jojo start taking notes. I have a sawzall we can use.

 

I'm ready coach!

 

The laser level was a genius level idea. I should've done that when I built my bumper...

 

Highly recommended, and a cutting wheel on a grinder! It was weird too because there was no “taco lean”, that’s a self leveling laser

 

That's gonna eliminate the guess work for doing the rear fenders when its time for high clearance!

 

I didn't even notice the laser, good idea

 

That laser level is an amazing idea!!!

FYI for people cutting plastic like the bumper. An Oscilating/Multi tool with the 3/4 circle wood blade works very well! stays straight while cutting, doesn't melt the plastic and requires very little clean up of the cuts.