looking for some critique on my 1st gen 4runner front bumper design (1 Viewer)

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

88TacoRunner

88TacoRunner

Joined
Jul 2, 2011
Threads
9
Messages
71
Wanting to make a front bumper soon for my rig and thought it'd be a good idea to utilize some classes at RCC I've been taking to make it all come together. I'm kinda going for the minimal look, like my rear bumper. Sorta mimicking the factory look then taking it a step further in design and strength. I also like to design ideas in the modular sense, so rather than one giant heavy piece it would be multiple smaller pieces that make up the whole. That way if an individual part gets damaged only one piece of the whole has to be replaced. Or for instance, I could make a piece out of round tube(s) for a different look, rather than square and design it to all bolt up on the same planes. The following is what I have rendered so far in Solidworks (the anchor shackles are kinda exaggerated but would be good for a pull stress test :), ideally they'd be somewhat inline with the mounting bolts on the frame)...

Isometric view....
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/32.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL]

Looking at right side off of front (d/s)...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/33.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL]

iso rear...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/34.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL]

top down...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/35.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/35.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/35.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/35.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/35.jpg"] [/URL][/URL][/URL][/URL][/URL]

front overlayed on rig...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/31.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL][/URL]


It's 5 pieces...the center section, the two front sides, and fender sides, maybe 6 if I make the stinger removable. The center section will bolt to the captive nuts on the frame, the front sides will bolt to the center, and the fender sides bolt to the front sides (you can see the two button-head allen bolts in the render). Most of it will be welded plate, cut and fit like a puzzle (not a terribly large or complicated puzzle), except the front sides which will probably be rectangle tube for ease of fabrication. Behind the license plate there will be an opening in which you could reach in and tighten the fasteners. Based on 1/8" carbon steel SW tells me it weighs about 50lbs. I might put some air slots in it somewhere for my p/s cooler. Right now I'm leaning towards makng the center section a bit more narrow and the front sides a little longer. Any suggestions, likes, don't likes? BTW, if anybody wants me to CAD up an idea, let me know, I'd be more than happy to discuss it....Dylan
 
looks nice.

i think it needs more beef and also needs to be off the body for any real protection.

.125 isnt going to survive long in real off roading.

an aftermarket piece needs to be able to take some damage away from the body to be usefull.

and the bolt together pieces can be damaged and tear up the rest of the bumper too.

sorry, im a Beta tester in my dream life.
 
Channel is a very poor structural member when used with the flanges facing directly away from the load. The flanges are unsupported at there outer ends and cripple easily allowing the member to fail.

A heavy wall rectangular or round tube would make a far stronger bumper

Example: A trucks frame, yes it is mounted on edge like shown, but the loads are mostly vertical not horizontal as is the case with a bumper, this puts the loads into the larger section that is stabilized by the flanges.

Channel can be used but it requires additional gusseting or braising to withstand the loads experienced off road

Weight is your enemy, align the material to accept the loads along its stiffest section this will optimize its weight to strength ratio.
 
Thanks for all the good feedback, gives me some stuff to ponder. I agree, there's not a lot of beef, I was trying to keep the weight down as much as possible, but 46 lbs is pretty lite. Any ideas what would be considerd too heavy for a daily driver as far as handling feel and MPGs? I will probably thicken the center and add some key gussets where it's mouted to the frame, then go lighter out from there. White City Metals has hundreds of linear feet of 2x5x1/8 or the next higher gauge size (14-12?) I've been eyeballing, I try to incorporate steel in the desgin that's already boxed for me, so I probaly use that for the front sides and see where that gets me before making the curve back, I'm gonna try to soften up those corners too, but try to keep the overall look. I'll put up some progress pics as they come...Dylan

here's a side shot I missed...

 
On the south side of the steel building they had piles of 3/16" x approximately 5" x 72" hot rolled scrap. I built two bumpers out of it and for the money it cant be beat.

Matt
 
progress

So a little update. I redesigned things a bit. I liked all the feedback. Yeah, I don't know what I was thinking with 1/8' for the main structure, probably that I just wanted it a bit beefier than stock and keeping the weight down, but it'd be nice to be able top tug on it too so that's probably going to be 1/4 when all said and done and the front light bar will probably be a little lower if I decide to place one at all. I also softened the corners up which is what I've tackled today. I renderd this for the new corner....

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/corner.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/corner.jpg"] [/URL][/URL]

Then rerendered it in pieces for the eventual Torchmate treatment. If I had access to a nice brake/bender that could be a 1 piece deal with just 2 welded seams..

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/cornerassmy.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/cornerassmy.jpg"] [/URL][/URL]


Until the TM gets setup I used the cutting torch then tacked it just to see if it was all going to work out. One nice thing is that the all the pieces can individually fit on a regular piece of paper so I can print them all out in 1:1 and then trace them on the metal so that was a plus. This is 3/16 from WCM. Here's the proto...

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04602.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04602.jpg"] [/URL][/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04600.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04600.jpg"] [/URL][/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04603.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04603.jpg"] [/URL][/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04601.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04601.jpg"] [/URL][/URL]

The end angle in the pic is a little deceptive, it actually lines up when you look at it straight on. At least I know the cut and trace method works like it should. Might refine it one more time...
 
That's cool. When you are done with that could you build my kid a full scale model of Optimus Prime? He would really dig it..
 
That's cool. When you are done with that could you build my kid a full scale model of Optimus Prime? He would really dig it..
Click to expand...

Hehe, name your price :). I wish I was that good, at least in modeling. Actually Kief your suggestion was the inspiration behind the new corner. I think you were right about it being too sharp (if that's what I was inferring), plus the angled corner adds a dimension I like...
 
88TacoRunner said:
Hehe, name your price :). I wish I was that good, at least in modeling. Actually Kief your suggestion was the inspiration behind the new corner. I think you were right about it being too sharp (if that's what I was inferring), plus the angled corner adds a dimension I like...
Click to expand...

I've smacked my shin or skinned a knuckle too many times around equipment or tools that was functional but not designed for safety or ease of use and working around. We'll see how I do when/if I ever build a bumper.
 
some more progress

Some more pics, it's been a little slow going but here's where I'm at so far. I thought some more about tugging on it so I decided to design the bumper around the pull points that way all the forces will, theoretically in my head, travel through the bumper to where it attaches to the frame. It'll tie into 4 captive nuts I have available, some bottom ones are obstructed by my front hanger though. Here's the concept, it's 1/4 and 1/2" plate.....

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturemm.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

Here's how I was thinking to mount the bumper to this part; make some square holes in the bottom of the center section and slide it over the mounts, tack it, unbolt the works, make sure it's true, then add some gussets from the mount plate to the upper portion of the center then 100% weld it. I'm also trying to keep the ends of the pull points about flush with the upper part of the center so there won't be a tendency to smack into them...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/Capturevcb.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

Here's the first part...

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04616.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

Then yesterday for the limited time I had at shop I cut and added the pull point. I actually made both sections but got sloppy in my haste on the second and totally screwed up the bolt pattern, so I only came out with one, plus I still need to add the bottom gusset to it...

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/jhj.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

I was trying to line it up with the frame for the most part...
[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04637.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"][URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04639.jpg"] [/URL][/URL][/URL][/URL][/URL][/URL]

I 've got two days of shop time left to bust this out for the sake of the machines I can use (if I can fully make it with my schedule). Not sure if it'll be done so there may be some downtime between semesters but hopefully it won't take too much longer....Dylan
 
Be careful you don't design something that looks great and works perfect. You will end up with a pack of Toyota Hounds wanting to know where to send their money and when their bumper is going to arrive on their doorstep! :D
 
Getting there

Thanks for the nice words guys :), I’d be doing backflips to work if I could do this for a living. Well, was told today that we’re shutting down Wednesday instead of Thurs so I probably won’t get it all done till sometime early next semester, I was really counting on that extra day. So today got the other mount made and cut the bumper to slide it over and tacked it to the mounts temporarily. Looked good at the shop so then GMAW stitch welded the seams shut to decrease warpage potential. Welds are getting better, kinda didn’t want to grind them but I’m not quite that good yet. Then took the bumper home so I could do some more test fitting. Here are some pics at home…

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04640.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04650.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04652.jpg"] [/URL]

Gratuitous weld shots, for me at least…

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04641.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04646.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04648.jpg"] [/URL]


So this worked out on a level I didn’t plan, these top bolts make good hangers till the rest are threaded, and they're the easiest to reach…

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04655.jpg"] [/URL]

The pulls are parallel as planned, although they look like they might not be out far enough; just by my eye they could be further out on a design level, I guess as long as there’s shackle clearance it’ll be okay. You can kinda see a roll back in the bumper, I’ll grind the tacks and true it up, I may slide the bumper back further, but not so much it makes mounting it any more difficult, then just run a single pass around the works front and back. It’ll be easier when I cut the access panel behind the license plate to mount it anyhow. At this point I can actually hand thread all the bolts, and a closed end ratchet crescent makes the rest go pretty quick...

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04662.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04659.jpg"] [/URL]

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04661.jpg"] [/URL]

Here’s the side clearance so far. I scribed the arc of the grill in the top of the bumper so I can cut it back to profile the arc for more clearance and for asthetics…

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04656.jpg"] [/URL]

Centers lined up very nice to the body, CL was on there before I mounted it, I promise :)…

[URL="http://i677.photobucket.com/albums/vv136/chilldyl77/DSC04668.jpg"] [/URL]

So far good, I'll put some more up Wednesday, hopefully I'll have the front sides on then, but probably not the corners and corner to frame tie...
 
What/where are you taking this class? Want in!
Click to expand...

Welding 101 at RCC through the table rock campus, the shop is actually at the VA DOM, and I'd highly recommend it. Based on what I've seen I think you'd do great in this program. Heck, it's only 261.00 for 3 credits which gets you in the door and access to the shop and darn near unlimited resources (gas, wire, rod, power, metal for practicing...some metal you can have). Although I'm taking it as part of my curriculum, for the price I might be taking welding 101 some more out of pocket just for the resources to be had. Plus the instructors are cool dudes, the real life welder types who know the ins and outs. If they see you doing good and completing the modules they'll let you use they shop for your stuff too.
 
I've done some reading on welding and I really don't know what I'm doing. A class would be really cool except I would have to redo everything I've ever done!

Nice work!
 
Last edited:
Kinda off on a tangent, an idea I've been toying with for some lights for the top of the bumper that look side to side. I had the idea when I was thinking of a use for an old p/w motor. The p/w motor won't work, but a servo will, and will give speed control. At this point it's just a crazy idea in SW...



Here's a link to some video of it in action...

http://youtu.be/216DHCLRgrI
 
ah yes the packard/tucker/tatra/citroen swiveling headlight idea. i always wondered when i was younger why this never took off. of course since the 60s cars such as Lincolns and Cadillacs have had an extra side light that kicked on with the turn signals, and now lexus is offering smart headliguts...
its a great idea, and i say if you can make it work and guarantee not getting stuck aimed blindingly at oncoming traffic, I'd love to see what you come up with!

i certainly commend you for thinking outside the box! perhaps a small, fast acting linear actuator style drive with repositioned sensor? *gears turning*

hey by the way im digging your low profile bumper design too!
 
You must log in or register to reply here.

Users who are viewing this thread

Total: 2 (members: 0, guests: 2)

Share this page

Back
Top Bottom