100 Series Rear Bumper Build (2 Viewers)

[mr2m1]

I was asked by a buddy in our Land Cruiser group to build a custom bumper for his 100 series. If anyone is interested, I have been “loosely” documenting the progress.

I downloaded a 3D model of 100 series to use as reference and for communicating a design to the owner. I then designed the bumper in Fusion 360 and placed it in the model with the cruiser.

Here’s the cruiser waiting for me to get started.

Time to remove the bumper, splash guards and tow hitch.

I designed this bumper to maintain the cross member. The cross member will help with towing capacity for the owners’ camp trailer.

Swing arm parts have arrived!

To be continued....

 

[excessive]

I really like the design. I would like to have something exactly like that myself.

 

[cmw]

I would be most grateful for as much de tail as you can provide!

 

[bucfl]

What year LC? I have a 2001 and need mud flaps. If your buddy is willing to part with them i would be willing to buy.

 

[mr2m1]

I spent several days doing a foam board mock-up. Even though I had modeled this in CAD the mock-up was needed to check fitment and the overall look.

What year LC? I have a 2001 and need mud flaps. If your buddy is willing to part with them i would be willing to buy.

Its a 2000. I will check with the owner.

 

[mr2m1]

Thanks for the comments.....back to the build.

I spent several days doing a foam board mock-up. Even though I had modeled this in CAD the mock-up was needed to check fitment and the overall look.I spent several days doing a foam board mock-up. Even though I had modeled this in CAD the mock-up was needed to check fitment and the overall look.

3/16” Steel loaded on the CNC. I don’t have an overhead lift, this was a major pain in the ass to place on there.

Parts to attach to the bottom of the frame and attach the “wings” with the main bumper.

Tacking the wings into place.

Tacking the main bumper into place.

This is the setup for the tow receiver tube. I have a video of the process but can’t figure out how to post on here. I used my plasma cutter to cut a 2.5” square through the cross member then drilled 4 holes for M14 grade 10 bolts and nuts. As mentioned earlier this should help carry the load for the trailer in addition to the bumper.

To be continued......

 

[Live to Ski]

I like it.

I'm assuming an engineering stress analysis was performed on the virtual model.

Also, aluminum considered?

 

[excessive]

Awesome work. Any chance you'd consider offering a DIY weld -together kit?

 

[mr2m1]

I like it.

I'm assuming an engineering stress analysis was performed on the virtual model.

Also, aluminum considered?

No I haven't done an engineering stress analysis on the model. To my knowledge Fusion 360 doesn't have that option.

To answer your other question. Im not a huge fan of using aluminum for this build, but it was discussed briefly.

 

[mr2m1]

Awesome work. Any chance you'd consider offering a DIY weld -together kit?

Thanks for asking but there is way too much I need to refine before I would offer these as a kit.

 

[mr2m1]

Moving on to the swing arms......

Cutting the 4X2 for the swing arms.

Drilling for the hinge tubing on the swing arm.

Hinge and part of the swing arm tacked in place.

Cutting 1.5 tubing for the ladder and tire carrier.

Making the bends for the tire carrier.

Tire carrier tacked into place and the new KM4 test fit for height.

Lowered the KM4 for a better center of gravity.

More posts tomorrow...

 

[mr2m1]

Both swing arms are in place. There is still a lot of welding, grinding, and sanding. I also need to fabricate the brackets for the tire carrier, latches and stops.

 

[cmw]

Which swing arm parts did you use?

 

[mr2m1]

Which swing arm parts did you use?

I ordered them from EMS Offroad's website.
EMS Offroad Link

 

[mr2m1]

Got a little more done yesterday.

Did some coping for the ladder rungs.

Everything was going good until I stripped the threads in the hole saw and had to get creative. I tried adding a washer and that worked for a minute then the hole saw caught the tubing and I stripped the threads again. In the end I just welded a chunk of steel onto the hole saw that had a hole in it that was threaded

.

Ladder looking like a ladder.

Today I cut and bent the bracket for the tire carrier and the supporting gusset.

Much more on the way.

 

[mr2m1]

Here is the tire carrier mostly welded up.

Drilling for the latch holes on the back of the swing arm.

Making a plate for the latch catch that mounts to the bumper.

These brackets will mount to the swing arms.

Everything test fitted before powder coating.

Without tire.

With tire.

 

[HotSoup]

Wow....that's some impressive fab skills.

 

[100d ua]

Any chance you’re selling the stock bumper cover lol.

 

[mr2m1]

Any chance you’re selling the stock bumper cover lol.

I'll send you a PM.

 

[NookShneer]

Wish I had a chance to see this in person. Looks amazing Jason!