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Working on a new rear bumper, want your guys opinions

Discussion in '1st Gen. Tacomas (1995-2004)' started by ForestRunnerFrank99, Nov 6, 2019.

  1. Nov 6, 2019 at 1:53 PM
    #1
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    So the next step for my truck is a new rear bumper. I looked around and didn't see any on the market I really liked, so I decided to design and fab my own! I really like the high clearance bumpers that require you to cut the bottom of the bed, so that's what I started designing. I took a lot of measurements of my truck and began CADing a new one. Go easy on me, this is a very rough prototype, but here is what I have so far (sorry for the pictures of the screen, I didn't take any screenshots but I will update when I get home):

    Top Right.jpg Top Back Left.jpg Top Back.jpg Front Bottom.jpg


    So the bumper will be made out of a 1/8 or 3/16 steel plate. It will be laser cut and welded together. I have access to a CNC laser cutter at my school so I should be able to do it for fairly cheap. I will post the dimensions when I get home but off the top of my head the bumper is 5" thick, has a 4" top, and 1.5" top on the sides.

    Next Steps: I am going to create a tire mount, bed protector hoops, frame mounting plates, finish the trailer hitch, and add tow hooks.

    What I am looking for is feedback from you guys. What would you like to see in an offroad bumper, what can be changed to make it better, any design flaws you see, etc.

    Thanks!

    EDIT: Updated the images!
     

    Attached Files:

    Last edited: Nov 8, 2019
    FishnTx and 04taccoo like this.
  2. Nov 6, 2019 at 2:09 PM
    #2
    Wyoming09

    Wyoming09 Well-Known Member

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    They look much better if drawn on the inside of cereal boxes .

    The important thing is that your happy don`t worry what other people think.

    How are you going to attach it ??

    plan on a receiver hitch ??
     
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  3. Nov 6, 2019 at 2:44 PM
    #3
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    Don't worry, the cereal boxes will be used.

    I haven't drawn them yet, but it will have 2 legs that bolt to the OEM bumper holes.

    For the receiver I was going to purchase one of these hitch receivers from ebay and weld it in with some gussets.
     
  4. Nov 6, 2019 at 10:31 PM
    #4
    ROlla-Xrs

    ROlla-Xrs Well-Known Member

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    Looking good
     
  5. Nov 6, 2019 at 11:29 PM
    #5
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    Thanks!
     
  6. Nov 7, 2019 at 8:45 AM
    #6
    drr

    drr Primary Prognosticator

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    If you are planning on adding a swing out to it, consider a fully boxed section around the hinge/spindle area. An open channel shape like you have drawn is weak in torsion and will cause your swing out to sag with a heavy tire, gas cans, hi lift, etc on it.

    Also consider “returns” from the side wings back to your frame to stiffen them. If you’re already cutting the bed sides this should be easy to do.
     
  7. Nov 7, 2019 at 10:38 AM
    #7
    xtremewlr

    xtremewlr Well-Known Member

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    Another option instead of fully boxed is a "kicker" bar like I added to my Coastal rear bumper. I can't post pics from work, otherwise I would. See my build thread tho.

    And take into serious consideration what you will use for a hings and lock for the tire carrier. I HIGHLY recommend using the parts from 4xInnovations for those 2 things. I rebuilt my carrier recently using those parts and they are superbly made and not super expensive. Worth the investment but you do need to consider them in the design since you are early in it still.

    https://www.4xinnovations.com/Swing-Out-Tire-Carrier-Hinge-Assembly_p_109.html

    https://www.4xinnovations.com/Swing-Out-Tire-Carrier-Latch-Assembly_p_110.html
     
    ForestRunnerFrank99 [OP] and drr like this.
  8. Nov 7, 2019 at 9:45 PM
    #8
    Fuergrissa

    Fuergrissa Well-Known Member

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    Current design is weak there will be a lot of deformation and deflection when you apply a load(bash it on a rock or use it in recovery).

    1) Like others stated reinforce the sides with tubes to the frame mounts.

    2) gussets to the interior or/and enclose it

    3) gussets to frame mounts to support recovery point/points

    4) swing out should be double shear like the link above. I like to use circular tubing as you get good strength to weight ratio.

    5) reinforce the side you plan to have the swing out pivot on

    6) keep the tire as close as you can to the tailgate/bumper and close to the pivoting side, this will help reduce the moment created by the tire and add gussets to the mount

    keep in mind the swing out is not just a static load, the vibrations from driving turn it into cyclic loading.

    Lastly highly recommend building a cardboard prototype with your dimensions before you send plate to the laser cutter. This will give you a good idea of things you might want to change.

    Most importantly take time and have fun.
     
  9. Nov 7, 2019 at 10:01 PM
    #9
    TacoBike

    TacoBike Well-Known Member

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    I would recommend that when you weld in the receiver, leave the end open. This is good for bending rebar and also really long hitches.
     
  10. Nov 7, 2019 at 11:13 PM
    #10
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    I was going to add some gussets to stiffen everything up. Good idea on the returns, I'll implement something in there. Thanks!
     
  11. Nov 7, 2019 at 11:19 PM
    #11
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    I like that hinge. It looks super beefy. I'll see what I can do to add it into the design. Thanks!
     
  12. Nov 7, 2019 at 11:23 PM
    #12
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    Gussets are definitely in the plan! You give some great advice, I will make a cardboard cutout for sure. The tire mount is going to be the most tricky part to get right to ensure it is strong and looks good. The one on the coastal bumpers almost looks like an afterthought.
     
  13. Nov 8, 2019 at 12:13 AM
    #13
    Fuergrissa

    Fuergrissa Well-Known Member

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    Don’t for get to keep it simple. For example the circular plate with studs (where you mount the tire).

    To get the circular hole pattern correct simply place a piece of paper over hole patten on the wheel (the backside, where is flat) and use a lead pencil and scribble to reveal hole locations. Then place the paper on the plate your mounting the wheel and center punch the center of the hole locations, drill a hole and make sure you get a interference fit with the stud. No measuring
     
  14. Nov 8, 2019 at 12:32 AM
    #14
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    Smart. I am probably over thinking lots of parts this haha.
     
  15. Nov 8, 2019 at 1:26 AM
    #15
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    Okay I got a lot done tonight!I got the hitch figured out, added the beginning of a tire mount, started adding gussets, and started with the frame mounts. Obviously still needs more work, but let me know how you guys think it's coming. Here are some updated pics:
    Top Right.jpg Top Left.jpg Top Back Left.jpg Back Top Right.jpg Top Back.jpg
    Gussets:
    Gussets.jpg
     
    Last edited: Nov 8, 2019
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  16. Nov 8, 2019 at 3:03 AM
    #16
    Blue92

    Blue92 Well-Known Member

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    Dunno if you have one nearby, but tractor supply co has some reese 6" receiver hitch tubes without the trim ring on front. Thats what I did for mine, tucked up under so nothing sticks out.
     
  17. Nov 8, 2019 at 7:34 AM
    #17
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    I have one about 20miles away. I'll have to go check it out! That would definitely clean up the look.
     
  18. Nov 8, 2019 at 7:39 AM
    #18
    eccracer104

    eccracer104 O.G. Member

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    @ForestRunnerFrank99
    Mine isn't a 1st gen, but my high clearance bumper has added supports like this -
    upload_2019-11-8_7-37-27.jpg

    (forgive my elementary line additions haha)
    This will add rigidity to the ends of your bumper, so if you come down or impact the side the leverage point isn't the rear corner near the tailgate.

    Hopefully this helps illustrate the idea.

    Awesome work an project! Excited to see this come together!

    Are you going to add any shackle points?
     
  19. Nov 8, 2019 at 8:06 AM
    #19
    Blue92

    Blue92 Well-Known Member

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  20. Nov 8, 2019 at 8:57 AM
    #20
    ForestRunnerFrank99

    ForestRunnerFrank99 [OP] Well-Known Member

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    I am going to add some supports exactly like that. I was going to put perpendicular to the frame mounts but I like the angle you have, I'll do it that way. Lol your picture is perfect! Thanks, me too! And yes I am going to add shackle points. I'm thinking 2 on the back about 10"-15" from the trailer hitch.
     
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