2014 GX460 DIY bumper build (1 Viewer)

[ddfunji]

Hello fellow 460 owners. Welcome to my DIY bumper thread

After some market research for front bumpers I decided on building my own. Ill be posting pictures and updates here on this thread so feel free to follow if you want to see what an amateur fabricator is able to come up with.

I don't plan on going into to much depth about the build process, its more just a place to share my progress and maybe inspire others to make a bumper that fits their needs. Dont expect blueprints, exact measurements, prestine welds, or absolute perfection.

Reasons I'm building my own
- Current selection for my year is limited. (2014)
- I want grill and headlight protection, which limits your options even more
- Basic features missing from cheaper base model bumpers that I'm not willing to pay an extra arm and leg for.
- Not able to find any DIY kits for my specific year
- Super long lead times currently (3-4 months for the few I was interested in)
- Personally not able to justify the price for the current options.
- I need a bumper by March/April
- I like making things
- I have access to a welder and plasma cutter



If you have made any armor for your GX please share, next for me is rock sliders and then rear bumper.


Edit: spell check

 

[ddfunji]

Ive already done some work before deciding to post a thread about it. So ill catch you up

I was having a hard time finding a cheap winch mount plate for the front for this year lexus (2014). I did find some hidden winch mounts by a few companies but wasnt happy with the price ($500-800) or lead time (1-2 months or backordered). Found a few options out of the states but still to pricey for what I needed. A quick craiglist search for 'winch mount' popped up all types of crap, but one stood out to me and looked like something I could work with.

It was only $70, had roller fare leads, main plate and mounting plates made from 1/4", mounting arms from 3/16", had winch holes already drilled. Owner said it came off a 2007 Dodge Ram 4x4

So I removed the front end, and factory bumper. At this point I could make rough measurements and see how this plate needs to be mounted.

Its hard to tell in the photos but the mounting brackets needed to move in a couple inches in order to land centered with the frame mounting points. The mounting plate needed to drop quite a bit in order for the winch to have vertical clearance. I was shooting for 8.5-9 ish inches of clearance for the winch. With the current length of the mounting arms the winch would stick out to much, so the mounting plate also had to be sucked in 2.5ish inches as well.


Edit: grammar

 

[ddfunji]

Fast forward a few days from the previous photos and we got the arms shortened, winch plate dropped a couple inches, sucked in a couple inches and new frame mounting plates made to which we welded the craiglist winch plate frame mounts to.

We used the factory bumper mounts to get the correct hole spacing on the new mounting plates that were made. We had some scrap 1/4" peices laying around.

We started with tacks and filled in with welds after we test fitted. Then had to make a smaller side plate for both sides so the bumper could tie into the side of the frame.

The factory bumper only uses the bolts on the front of the frame, I noticed a threaded hole on the side and figured the bumper should tie in there as well. (its a different size then the front bolts)

I seperated the honey comb from the top grill piece, hack sawed the bottom part off, and cut some of the inner fender.

Now this gives me something to work off of, the rest of the bumper will be built off of this 1/4" winch plate using 3/16" for the most part and a little bit of 10GA. I havent decided the rest of my lines yet so thats why I didnt cut any more plastic off.

 

[re_guderian]

Looking forward to it! I agree, the selection for the 460 is a) slim, b) expensive, c) unobtanium, and d) fugly for the most part.

 

[ddfunji]

Rough draft for the front piece.

Front piece cut, cleaned and clamped

The next couple pieces, start to angle the bumper upward (the outer 2 small pieces are upside down in this picture, this was fixed later)
Also tacked everything

The first two pieces on the bottom

Outer pieces rotated and re-tacked. Using a lazer level and tape i got my straight lines marked on the bumper, verified with lazer and measuring tape.
This part was hard, especially becuase I dont know how im going to finish the bumper quite yet. I played safe and cut the least amount of plastic that I needed.
I will probably ended up trimming more off.

 

[ddfunji]

Going to be test fitting the winch next before i get to carried away. Got to make sure it fits...

 

[ddfunji]

Im still alive, just been busy, also not very good at documenting the progress. I get carried away and forget to take pictures of every step.

Before I got too carried away with the rest of the bumper I wanted to check the clearance of the winch and also the control box. The clutch handle just barely touches the bottom side of the grill and was still functional. The control box would not fit on top of the winch, I kinda knew this was gonna be the case from the get go. Its not pictured here but the control box does fit on the back side of the winch facing the radiator. The control box can also be mounted wherever the cables allow it to reach.
This was mounted using the pre exisitng holes that were already there. I later decided to move the winch inward about 2ish inches. (Pictured later)

After feeling ok about the winch and knowing that ultimately it will fit I proceeded with closing the bottom up a little more. These bottom pieces were a little trickier, lots of different angles and working upside down on the ground. I used cardboard to get the genreal shape, then I check if that cardboard shape will work for both sides (In theory it should). I then transfer the shape to sheet metal and plasma cut it out. Clean my edges, and grind as necessary to achieve a good fit.

Moving back to the top of the bumper, these top pieces ultimately decide the top line of the bumper, lots of stressing and double guessing and ultimately saying "good enough for me". Also work on the back sweep and curve around the headlights

Cut the plastic back to its final resting place so we can start capping off the top of the bumper. All that work to not cut too much plastic and I ended up cutting to much plastic. Fail. Ill work something out later.

 

[ddfunji]

Top getting plated off, ran the metal about 3/4" to an 1" past the plastic.
Such a massive lip for a few reasons: 1: Accessory mounting surface 2: A good step for working inside of the engine bay 3: 1 3/4" inch bars need a mounting surface.

With the top looking good I finshed the inside of the tire well. You can see here were I might have cut to much plastic. It could also be an issue with were ended the bumper. I could have fabricated the bumper to fill this space where I cut too much plastic. Ultimaletly If it bugs me enough I will address it one day.

To add side support as well as regidity I tacked in some 1"x 1 3/4"x 3/16" tube laying around. This connects the side of the bumper to the bumpers mounting plate.
You can also see the winch in its new position with the clutch handle clearing the grill. After this we tacked some more spots and made sure everhting was looking good before taking it back off the vehicle.

Cleaned up the weld areas and began filling in. I do a lot of the shaping and grinding with a big ass 6 inch corded grinder, and then polish and clean up the lines used a a smaller grinder with a 120grit sander wheel. At this point it was getting late and I needed to get the bumper back on the vehicle for a camping/road trip.

Threw on the +5hp theft deterent shackles so I dont have to use the factory provided recovery points and BAM shes a bumper.

 

[ddfunji]

Still not done yet but Im back from said road trip and the bumper didnt fall off

Next up
-Cut out and Install fog lights + mount
-Fabricate and install headlight and grill protectection using 1 1/2" or 1 3/4" steel pipe
-Fabricate and install inner trust pieces to fortify the bumper
-Install autmotive rubber trim for plastic
-Determine final resting place for winch controler box.
-More lights?
-Sand and paint (Truck bed liner black)

 

[r2m]

Are you planning on doing the rear and rock sliders also?
Sliders are easy. A couple of buddies an I did some weld-on's for his full size Bronco some years ago. Banged them out in a day with my tube bender and welder. Albeit, they were just a simple tube design, no kick-outs or plating on top.

 

[JDUB fab]

Awesome work dude! Love seeing DIY fabrication on our rigs. Hoping to start my rear bumper build this spring.

 

[ddfunji]

Are you planning on doing the rear and rock sliders also?
Sliders are easy. A couple of buddies an I did some weld-on's for his full size Bronco some years ago. Banged them out in a day with my tube bender and welder. Albeit, they were just a simple tube design, no kick-outs or plating on top.

Ya I'll be building sliders and rear next, mainly so I can keep the same design consist across all three pieces. Sliders look easy enough and I imagine the rear bumper will be easier then the front. Im probably going to do bolt on instead of weld on. Im on the fence of getting tubes bent for me locally somwhere or investing the 100-200 bucks for a bender. Ive seen lots of great work done with the harbor freight tube bender.

 

[ddfunji]

Awesome work dude! Love seeing DIY fabrication on our rigs. Hoping to start my rear bumper build this spring.

Thank you! I love seeing DIY projects as well, they've been a big inspriration to attempt to do something myself. I wish you much luck on your bumper.
Share the process with us if you can!

 

[jiggletits]

Yikes. Everyone has to start somewhere... but to save you some trouble I have seen a lot of DIY bumpers fail when they got put to real use and it is not pretty. When that happens, kiss your fenders goodbye.

I would recommend you do some homework on how a company like ARB mounts their bumpers to a truck's frame, as well as how they reinforce everything from behind your crumple zone all the way out to the fairlead all in a straight line. Unless some pictures are missing, you're looking a little flimsy where it matters.

 

[r2m]

Ya I'll be building sliders and rear next, mainly so I can keep the same design consist across all three pieces. Sliders look easy enough and I imagine the rear bumper will be easier then the front. Im probably going to do bolt on instead of weld on. Im on the fence of getting tubes bent for me locally somwhere or investing the 100-200 bucks for a bender. Ive seen lots of great work done with the harbor freight tube bender.

The initial cost of a bender is minor compared to what the dies cost for each diameter and bend radius of tubing you want to bend.
I have this one: Model 32 Tube Bender Manual - https://www.jd2.com/model-32-tube-bender-manual
And wish I purchased the hydraulic version, but I can still get the attachment.
Just note that you need to pick your dies very carefully for what you're going to build. Dies alone are between $200.00 to $300.00 each. I have just a 1.5" and 2" dies.

 

[JDUB fab]

The initial cost of a bender is minor compared to what the dies cost for each diameter and bend radius of tubing you want to bend.
I have this one: Model 32 Tube Bender Manual - https://www.jd2.com/model-32-tube-bender-manual
And wish I purchased the hydraulic version, but I can still get the attachment.
Just note that you need to pick your dies very carefully for what you're going to build. Dies alone are between $200.00 to $300.00 each. I have just a 1.5" and 2" dies.

I’ve got a JD2 as well I think the 32, and yeah dies are freakin expensive. Plan is to add hydraulics in the future. Currently only have a 2” die. Keep debating on a tube rear or plate, probably will go plate to match the front, or hybrid.

I know it’s not offroad stuff but currently welding some silicon bronze castings.

 

[r2m]

Interesting art, is a new type of Batman?
If go with a tube rear bumper, you could trim your rear bumper valance up high and then run a steel hoop along the bottom edge from the rear fender all around to the the other side. That would protect the bumper from steep approach angles and you may even be able to mount a tire carrier on it?
Personally I love my MetalTech rear bumper, almost for the sole purpose that when my swing out and rear door is open, I have almost a full 1 foot of depth to sit, work on, lay things out, etc. extending out. It's the closest thing to having a tailgate.

 

[ddfunji]

Yikes. Everyone has to start somewhere... but to save you some trouble I have seen a lot of DIY bumpers fail when they got put to real use and it is not pretty. When that happens, kiss your fenders goodbye.

I would recommend you do some homework on how a company like ARB mounts their bumpers to a truck's frame, as well as how they reinforce everything from behind your crumple zone all the way out to the fairlead all in a straight line. Unless some pictures are missing, you're looking a little flimsy where it matters.

Thank you for the input. It's not done yet, but I'm sure it will serve as a much better bumper then the previous one once it's all said and done.

 

[ddfunji]

The initial cost of a bender is minor compared to what the dies cost for each diameter and bend radius of tubing you want to bend.
I have this one: Model 32 Tube Bender Manual - https://www.jd2.com/model-32-tube-bender-manual
And wish I purchased the hydraulic version, but I can still get the attachment.
Just note that you need to pick your dies very carefully for what you're going to build. Dies alone are between $200.00 to $300.00 each. I have just a 1.5" and 2" dies.

Thank you, I'll look into them.

 

[ddfunji]

Its been more then a month so I figured I'd post an update, I finished some more bracing a while back, only got one picture...

Did some final tacking and welding, polished some lines with the grinder, and painted it truck bed liner black, changed the roller fair lead for basic black one that came with winch, mounted the turn signals, trimmed vehicle plastic using 1/4" ID rubber air hose. Alot of this process I didnt document or take pictures of. I have been super busy withn the season change and havent been very focused on taking pictures of my projects.

So far happy with the outcome and design. Winch saved my butt the other day when I slid into a ditch. There is a short in the wired remote that I need to address, or setup the wireless remote that came with the winch.



I still need/want to do:
Grill and head light protection
Small skid plate/cover to protect bottom of radiator better
Fog lights? Light bar?
Some additonal welding and support on bottom lip of "side wings". Close some more gaps up with thinner steel
Weigh bumper, its heavy.
Remount winch controler box?