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Stucko's Bumper Build

Discussion in '1st Gen. Builds (1995-2004)' started by StuckoYota99, Feb 23, 2013.

  1. Feb 23, 2013 at 8:46 PM
    #1
    StuckoYota99

    StuckoYota99 [OP] Member

    Joined:
    Nov 26, 2012
    Member:
    #91909
    Messages:
    12
    Gender:
    Male
    NW Washington
    Vehicle:
    99 Toyota Tacoma
    2.5 OME Lift Dakar Leafs, 882 coils Custom Bumper Custom Headache rack
    Hey all, thought i would share my bumper build i did this fall. I wanted something unique that no one else has. i have seen ones similar but none like mine. Im not goin to go into all the dimensions and details unless someone requests it.
    Huge thanks to my dad Frank Sr. and my bud Jeremy!
    Let me know what ya'll think. I have a rear bumper bent in a similar fasion that is currently on hold until my schedule clears up.

    Well i started out with a 4'x8' sheet of 1/8" sheet metal.
    Had the top and bottom bent when i was in California.
    Winch is a Smittybilt xrc8
    DSCN1758_zps92631e2d_6b5e009f7854c9ecc51e8b9a96fea77bc95db7fc.jpg

    Basically the top was broke at a 90 and the bottom at a 45.
    DSCN1692_zps6bac6bb9_1fb7cf1431d06a981c7610861d0b40d4a8aa1f43.jpg

    We removed the front bumper and the crush caps
    DSCN1699_zps905627c5_67382894931325a482d577cef55dcb968318c2a1.jpg

    From there we welded two pieces of 3/16 angle onto it and welded the winch plate between the angle.
    DSCN1693_zpsbd4dca3d_34fc021fac3cbd6c1c1e6914f40a49f826ecb43d.jpg
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    DSCN1765_zps536df59e_7f58cb28c242765dd58b32a81e5e25e3181ed761.jpg

    After the winch plate was in there we set the winch and got the measurments for the hatches and the fairlead mount hole.DSCN1763_zps7dc041e1_e36c04e429c5c0e688c798e3fe7ea96a89e8da75.jpg
    DSCN1766_zps1ab6ef3a_6522fcc1ce99b99024d4f40516843b57ff6e346f.jpg

    We bent the metal by muscles and welded it in place. My buddy was over nearly every night to help.

    DSCN1769_zps0db07c31_5be02c64ef3aeec3e9a3ee3d9fdcbc109360edb6.jpg

    Then we cut another pie piece out and bent another section, under the wise old mans supervision of course. Im not good at finess stuff so my Dad helped out so i wouldnt screw up the project! Bless his heart.

    DSCN1795_zpsdf9a31b9_4ebe206abed1d74936933bdb527523aa11e31fc5.jpg
    DSCN1796_zps063a77e4_44f531b048c601ecc94a30d6ba4743aeb4c88dd9.jpg

    We made the last cut and bend and welded it. after the last bend was made we welded 2" peices on the bottom to match the 45 that was originally bent.[​IMG]

    We measured out the turn signal holes and planned on welding wire mesh to protect the blinkers. so i used a hold saw on the drill to make the corners. i kinda got carried away since we were planning on cutting the whole section out. i liked the design so i kept it.
    Picked up 2 pairs of led turn signals. mounted them on plates with a 45 bend on the bottom to protect them from mud. The reason i went with a pair is so they would be bright enough and wouldn't draw too much voltage.

    DSCN1810_zpsa3867fc8_3ba91b777b3c9110cf72148163e0b17105e57664.jpg
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    DSCN1836_zps766f5efb_7fe20d798f2b5af0aefafee8e56cb2c9f1f6c004.jpg

    When we had it on the truck we noticed that there was a quite a gap between the grille and the bumper so we welded and fabricated a skirt to go around. We welded gussets and supports on the inside and two braces out to the sides. Took the grinder with a sanding wheel and smoothed it as soft as a baby's bottom.

    DSCN1833_zps91f0d157_ba57d9fc278b458b1ff5e1342db1d9f029d08a41.jpg
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    Went to the local carquest, since the napa and oreilys didnt have any decent off road lights.
    Picked up two 4.5 inch led spot lights. Prolight Guys was the brand. very bright with low volt draw. waterproof and shock proof. definitely recommend.

    DSCN1839_zps7ca44053_e030df82ec0b834e6598a3e324b60cf5ac209a62.jpg

    Took a grinder and cut a 5 1/4" hole ish...it was kinda rough. but nothing that a welder and grinder couldn't fix. Then took 5" schedule 40 pipe and cut and welded it flush with the bumper. then cut a piece out and welded the mounting brackets onto the pipe. I don't have pics of this until it was primed.

    We took 1" square tubing and made a set of fairlead protectors. welded some gussets onto it and later had to cut them out with the grinder so the fairlead would fit (whoops) Also welded large D-rings onto the front.

    Primed it several coats and painted it a gloss black. unfortunately the paint we used was CRAP and would not harden. either i didn't put enough hardener in oooor the paint was 3 years old...oh well it eventually hardened and i already put it through its paces so the scratches don't matter.
    DSCN1916_zps3a63d6fc_0502576b6a2c4bfb30a73e6692145796b8ec51b0.jpg
    DSCN1915_zps511ff6e7_a3576183fa4b847fde52c7d4632de9becbc9756d.jpg

    My old man posing in front of the freshly painted bumper.
    DSCN1918_zps8e9d89bb_a31b91b9fa8a4390cadc020038f7f57a2ea9a687.jpg


    While the paint was drying i ran my light and winch wiring. I also mounted my switches on my dash where the compartment was. The reason i have 4 switches is for my bumper lights, headache rack piaa lights, my rear bed light and the last one is for my soon to be back up lights on my rear bumper which is on hold right now.
    DSCN1920_zps4765cb17_8fb072a1977c9c31d60a27bb93e20fe27c6686d2.jpg

    The winch hatches worked perfect. they are pop riveted onto the bumper and weather stripped it to protect it as best i could. one side was for the electrical box and the other side was for the clutch.
    DSCN1928_zps98890a61_57f7b7a625fc40b739afaba833b66c99e03949da.jpg

    Went to do the final mounting aaaand the bolts refused to line up but nothing a little muscle and a pry bar couldn't handle. Game on.

    DSCN1921_zpsfbf94d3c_ece53cc7decce1a6242a14e2fb2ef24afc08ff38.jpg
    DSCN1923_zps0ed7d649_25be1ad9906e2660e1eb5adad25ab6e293ba4eaa.jpg

    Dog Approved. they had been supervising throughout the build.

    DSCN1930_zpsf840e5f7_ffa092ba2ebec5fe088dd0921813b46cf8e63e47.jpg
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  2. Feb 24, 2013 at 6:23 PM
    #2
    01GREENTACO

    01GREENTACO Not all who wander are lost

    Joined:
    Aug 21, 2008
    Member:
    #8672
    Messages:
    1,266
    Gender:
    Male
    Germantown, TN
    Vehicle:
    01 4WD
    Lost track many, many mods ago.
    Looks good! Real good. I had an XRC 8 about a year ago but ended up selling it. I wish I would have kept.
     
  3. Feb 25, 2013 at 9:07 AM
    #3
    ruggedT

    ruggedT The Sticker Guy Vendor

    Joined:
    Jun 24, 2011
    Member:
    #58788
    Messages:
    3,181
    Gender:
    Male
    First Name:
    Stan
    Midlothian, Va
    Vehicle:
    2016 Ford F250
    Diesel on 35's
    Nice job man
     
  4. Feb 25, 2013 at 9:19 AM
    #4
    BAMFTACO

    BAMFTACO Another day another beer

    Joined:
    Feb 3, 2010
    Member:
    #30639
    Messages:
    10,686
    Gender:
    Male
    First Name:
    Jośe
    Woodlandland hills , CA
    Vehicle:
    Taco
    Lift- king 2.5 with light racing uppers,tc coil bucket gusset, 4 in spindles,timbern bumps all around ,wheelers 3 addaleaf, ato shackle flip kit with 6 inch HD shackles. Armor- tire gate, custom tube bumper, kr fab rear bumper,trail gear wiy 78 in sliders Performance-intake manifold spacer, hps silicone hoses Random stuff- kenwood head unit,b&m t shifter, hood bug deflector, rear dust lights with custom bed bar and hi lift mount.
    Nice that thing is beefy
     
  5. Feb 25, 2013 at 1:46 PM
    #5
    StuckoYota99

    StuckoYota99 [OP] Member

    Joined:
    Nov 26, 2012
    Member:
    #91909
    Messages:
    12
    Gender:
    Male
    NW Washington
    Vehicle:
    99 Toyota Tacoma
    2.5 OME Lift Dakar Leafs, 882 coils Custom Bumper Custom Headache rack
    Very beefy, in the end without the winch it weighed approx 100lbs then another 80lb with the winch, i may be off on the winch weight. but i recently put in OME 882 coils and i dont have any additional front droop.
     
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