FJ45 Bumper/Bullbar Build

[Inventure]

Thought I would post some pics and info on the bar I just built. I was keeping an eye out for a standard bumper to fit up as I didnt want to fork out for a full bullbar new over here. After watching the first original bumper I found sell for over $300AUD, I decided I would build my own.

I started with a 3.0m section of 100 x 50 x 4.0mmWT Galvanised U-Channel, and a section of 100 x 10mm plate I had lying around.

This is the before shot with the Thomas PTO winch...

 

[Inventure]

After cutting the plate to size, I then had to notch into it a couple of mill to make sure the U-Channel would fit over the plate, and at the same time allow the U-Channel to sit flush with the bottom of the winch.

I drilled the plate section and bolted that in place to the chassis, then held the U-Channel over the plate and in place while I tacked it together.

After it was tacked I measured in 175mm from the end (1500 total length) and marked out a wedge to be cut out top and bottom on both ends to allow for the bend.

 

[Inventure]

The first pic is of the outside of the weld - it looks like penetration right through, but its not, thats actually the galvanise coating melting as I welded.

I used the other 1.5m of U-Channel I had to clamp a wedge onto the one and bend either end in - once that was done I welded the wedge and ground it down.

The last 2 pics show it finished for now - I still need to do some reinforcing for the winch - I'm thinking a small 2" hoop over the top with some plate angle running from the top of the tube down to the U-Channel. That will allow me to mount the fairlead higher up to align with the top of the winch drum, and it will also give the winch frame something else to 'push' against. At the moment if I use the winch all the stress is being put through 4 bolts that just bolt down from the winch into the chassis which is not ideal.

Overall, so far I'm really happy with the look. It actually looks better in person - very factory and simple I think.

 

[TOBASH]

Can't believe no one else commented on this.

Nice work.

Great idea.

What will you do to prevent rust in the areas you cut and no longer have Zinc?

Best,

T

 

[Bang Bang]

Very nice work.....love those trucks BTW.

 

[Inventure]

Where the welds and grinds are I have cold galled at the moment. I still and yet to finish the hoop and winch reinforcing, and once I do that I'll get the bar powdercoated.

Thanks for the nice comments - I thought maybe noone liked it...

 

[Shagger1]

I like it-it looks great-its cheaper and stronger than the fact bumper too!
Also, great pics-if someone was going to do they same they have the plans right here!
Top effort.

 

[reddingcruiser]

Very nice work.....love those trucks BTW.

You mean the trucks with the steering wheel on the wrong side.

 

[Bang Bang]

You mean the trucks with the steering wheel on the wrong side.

Ha ha......if it's a 45 sitting in my driveway, I wouldn't care what side the steering wheel was on. I will own one some day......maybe when the kids are gone and I have money I don't know what to do with.