Can't buy the bumper I want, so I'm going to build it... (1 Viewer)

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ended up going w/ a shop that had a CNC plasma machine. the winch plate, frame brackets, and center section is 1/4", the bumper "skeleton" is 1/2", and the wings are 1/8" on the prototype. i can tell you now that the center will be 1/8" as well, and we will probably go ahead and cut a new one. i wanted 3/16", but they didn't have any drop for fitting this first one together.

tomorrow we will be bending the pieces on a 10-ton press and tacking some up for initial fitment.

now that i have the shop w/ CNC table and press, the welder/fitter is ready to go, i'm all set. i have the powder coating shop on notice, and the greyhound bus terminal is only 100-yards from my day-job desk. we also have a freight dock here with regular drop offs and pick ups, so UPS or FedEx freight is also a decent shipping option.

First cuts in the 1/2" plate:
cut1.JPG


Pieces ready for the press:
cut2.JPG
 
Yeah, 1/4" is too thick for the center if the winch is directly mounted to the frame. Its just the drop piece they had. If the winch is mounted to the bumper, then 1/4" is right. 1/2" is for the "spine" of the bumper on each side of the frame rail - about .6 sq ft for each piece. Production would have the winch tied to the frame and a 1/8" steel facade over it.
 
just so you guys know what is designed for a 2000, and subsequently a 1998-2002 Land Cruiser MAY or MAYNOT work on a 2003-2007 & the 1998-2007 Lexus LX470. Now I say MAYNOT because the years/models I stated have an extra lip under the headlights/grille. If it does interfere, the only thing the end user will have to do is trim back the bumper top edge. Nothing crazy just want to make everyone aware.
 
1loudLX said:
just so you guys know what is designed for a 2000, and subsequently a 1998-2002 Land Cruiser MAY or MAYNOT work on a 2003-2007 & the 1998-2007 Lexus LX470. Now I say MAYNOT because the years/models I stated have an extra lip under the headlights/grille. If it does interfere, the only thing the end user will have to do is trim back the bumper top edge. Nothing crazy just want to make everyone aware.
Click to expand...

The 06-07 LC grill and headlight set up is completely different (incorporating a hidden lower valance) from previous years and does not fit without mods.
 
thanks for the heads up. i knew that there were differences, but not exactly what those differences entailed. i hope to get a local owner interested and use them as a guniea pig for subsequent 03+ revisions.
 
Very cool to see it coming together. Would prefer to buy the pieces cut already vs the template.
 
Phil, I don't suppose you took a picture of the "valence" when you had it apart, did you?
 
uzj100 said:
Very cool to see it coming together. Would prefer to buy the pieces cut already vs the template.
Click to expand...

To help keep costs low for development and fabrication, I'll probably offer up completed bumpers in the first run (6-8, depending on what we can fit per sheet of material). After that, I'll have to play it by ear as to what is offered. My welder has a 92 Toyota Truck that we're going to hang some steel (front bumper sorta like this one) on next.

Next spring, you can plan on seeing a rear UZJ bumper - but probably w/o a tire carrier...
 
my welding skills are improving, so I'd be interested in the drawings/templates...
 
bamachem said:
ended up going w/ a shop that had a CNC plasma machine. the winch plate, frame brackets, and center section is 1/4", the bumper "skeleton" is 1/2", and the wings are 1/8" on the prototype. i can tell you now that the center will be 1/8" as well, and we will probably go ahead and cut a new one. i wanted 3/16", but they didn't have any drop for fitting this first one together.
Click to expand...

This bumper is going to make all other seem like a tin can:cool:

Do you have an estimated weight?
 
We're just working with some of the final fitting today. Turkey day threw a wrench in getting anything done since last Wednesday. Tomorrow we will be fitting everything to the truck and I'll take some pics along the way. We're going to have to work on the winch mounting plate a little to get everything to lay out where it needs to go with the foremost frame crossmember.

Once this bumper is mocked up, the CAD files will be modified with the new dimensions needed, then another bumper will be cut from new stock steel and fabbed up from scratch on the truck to make sure all the lines work and new dimensions are correct.

So far, it's looking pretty good!
 
Ran into a couple interferences on the fab up that needed to be worked out in CAD, recut, then re-bent.

Final thicknesses:

Frame Mounting Bracket: 1/4"
Winch Mounting Plate (direct to frame): 1/4"
Bumper Mounting Plates (at frame rails): 3/8"
Bumper Skin: 1/8" (thicker than ARB and TJM)

New plate will be cut and bent by lunch tomorrow. Part of the reason it's taking so long is because we're doing a 91 Toyota P/U at the same time with a very similar style bumper. The UZJ will be tacked up first (tomorrow after lunch) and hopefully welded out by quitting time. I'll take pics of the build-up along the way.

The P/U bumper will be completed over the weekend, then they will both go to the powder coater next week.

Plan for later this week will be for me to get the CAD drawings finalized (dimensional changes from what we learn at fab-up) and we will probably go ahead and build the first "production" bumper next week. Any additional tweeks to the CAD files will be done after that bumper is complete. After that, we should be ready to go.

For now, looks like pricing will be $800-$850 range + shipping for a complete, welded out, powder coated bumper with winch plate for the frame on a UZJ (no hoop). Kit *may* come later with the pre-cut and pre-bent pieces, un-coated and/or un-painted of course. These would be in the $400 range and would require only a 3-4 hours to do final fitting and welding, then finish coating (paint or PC) of your choice.

Pics tomorrow! ;)
 
I can't wait.
 
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