Work In Progress - Dobinsons Rear Bumper Installation

[OwnerCS]

Since I haven't seen a thread for a Dobinsons rear bumper installation, I want to start this one. I will combine any installation tips and pictures that anyone can contribute to this thread.
Also, it will give me an incentive to keep the project moving. I will be following the Dobinsons instructions with some tips that I learned from a guy on FB.

https://cdn.shopify.com/s/files/1/0029/2795/1981/files/BW80-4109_Instructions_1.pdf?v=1582756645

As a first step, I want to get the wiring in order. More to come.

Here's the end goal picture below.

 

[OwnerCS]

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[OwnerCS]

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[OwnerCS]

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[OwnerCS]

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[GatorBait1551]

Dobinsons rear bumper install with pictures

Not a whole lot of info on these bumpers here, so I figured I would share some of my thoughts and pictures from my install. I picked this bumper for a few reasons. 1. In stock read to ship. 2. Ability to run dual spares on the rear 3. Integrated lights, I'm a big believer in visibility. 4. It's...

forum.ih8mud.com

 

[OwnerCS]

Dobinsons rear bumper install with pictures

Not a whole lot of info on these bumpers here, so I figured I would share some of my thoughts and pictures from my install. I picked this bumper for a few reasons. 1. In stock read to ship. 2. Ability to run dual spares on the rear 3. Integrated lights, I'm a big believer in visibility. 4. It's...

forum.ih8mud.com

Thanks for sharing. This helps. I know I have some wiring challenges with some changes that were made earlier in the 470's life. Cleaning up wiring issues are the hardest part for me.

You have a great garage. Unfortunately, mine is full and I'll be doing this in the driveway.

 

[yukon]

Thanks for sharing. This helps. I know I have some wiring challenges with some changes that were made earlier in the 470's life. Cleaning up wiring issues are the hardest part for me.

You have a great garage. Unfortunately, mine is full and I'll be doing this in the driveway.

If you have any questions let me know, it isn't that hard, but its made harder by dodgy instructions

 

[yukon]

I was going to post a pic, but the FSM has it on three different pages.


For a 1999 LX470

Green White is the stop light wires
Red Black is the reverse lights
White Black is ground
Green Yellow is right turn
Green Black is left turn

Of course I would verify this info before cutting, but this will cut down on guess and check

 

[OwnerCS]

Here's a proposed wiring map with pictures of the wire locations that are behind the tail/turn/brake lights and the backup light in the tailgate.

How does this look?

 

[OwnerCS]

Last night I spent some time going through bolts, screws, washers, nuts, basically all of the little parts that came in a couple of bags. I counted each part item and rebagged them in baggies with the numbers from the boxes. These identification numbers are used in the installation diagram.

I did find a couple of problems with the small parts. I did not receive any square washers. Though I found more round in that approximate size than needed. I guess the fulfillment department decided to start using round washers instead of square?

I did come up short with the M8 and M10 bolts highlighted -- maybe 3 overall.

Also I have some extra nuts and bolts that I see being used that are not on the list.

Bottom Line - I need to make a run to the hardware store this afternoon to complete the parts list before I start trying to mount the bumper.

 

[OwnerCS]

Did any of you guys find a need to tap out the nuts on the arrow-shaped mounting brackets?

I started finishing up the side bracket installation and found one bolt would not start. So I remoived the bracket and was able to start the bolt from the back side.

It turned to a point then locked up as shown in the pictue with the red underline below.

So the arrow bracket from one side with the green lines is fine. The bolts start without issue.

I guess I wll need to go buy a tap to tap out the nut on side the the red lines.

I know this looks like a fluke.

Has anyone else had this issue?

Oh yeah. I only received three bolts for the brackets. So I need to make a run to the HW store to buy the 4th bolt.

 

[OwnerCS]

I picked another M12x1.5 bolt from Ace Hardware. A bit longer but it will work.

The problem I'm having is the nuts were crooked when welted to the mounting plate. You can see how one of the bolts is tilted off to the side.

Would you remove the plate and go find a welder that can correct the alignment of force it on which really looks bad in the 2nd photograph?

This thing is really going to look bad if I keep going.

 

[OwnerCS]

After going for a larger 19mm by 40mm bolt with a nut behind it, I was able to finish the left side.

 

[ClassyJalopy]

I picked another M12x1.5 bolt from Ace Hardware. A bit longer but it will work.

The problem I'm having is the nuts were crooked when welted to the mounting plate. You can see how one of the bolts is tilted off to the side.

Would you remove the plate and go find a welder that can correct the alignment of force it on which really looks bad in the 2nd photograph?

View attachment 2467845

This thing is really going to look bad if I keep going.

View attachment 2467847

I am careless and hasty, so I would just torque that up, not like you would need to remove it often!

 

[OwnerCS]

I am careless and hasty, so I would just torque that up, not like you would need to remove it often!

I did that too.. Then the heavier grade bolt stripped out the nut. I had to put an M12 1.5 nut behind it. Maybe I can get it lined up ok.

The question I have at this point is which bolts to mount first? Should I mount the u-bolts to the frame with the L brackets first, then mount the bolts in the brackets on the ends before the center spacer and bolts I'm working alone which makes it a bit dangerous.

I'm thinking about using an engine hoist to lift the bumper and guide it into position before bolting it up.

 

[ClassyJalopy]

I did that too.. Then the heavier grade bolt stripped out the nut. I had to put an M12 1.5 nut behind it. Maybe I can get it lined up ok.

The question I have at this point is which bolts to mount first? Should I mount the u-bolts to the frame with the L brackets first, then mount the bolts in the brackets on the ends before the center spacer and bolts I'm working alone which makes it a bit dangerous.

I'm thinking about using an engine hoist to lift the bumper and guide it into position before bolting it up.

Hopefully, @atnolan94 or someone else will chime in with the specifics. When I was installing ARB front, I didn't have a helper, so I used a few 2x4s to hold different parts of the bumper up and align it to my my liking and then started tightening up the bolts. In general, if you have access to the back side, I prefer putting in free nuts vs, using captured/welded nuts.

 

[OwnerCS]

Hopefully, @atnolan94 or someone else will chime in with the specifics. When I was install ARB front, I didn't have a helper, so I used a few 2x4s hold different parts of the bumper up and align it to my my liking and then started tightening up the bolts. In general, if you have access to the back side, I prefer putting in free nuts vs, using captured/welded nuts.

Good idea. Thinking out loud. I might be able to stack up some tires and wheels that I'm not using to rest the bumper on it while getting it into position.

 

[atnolan94]

Set it up on some jack stands. Thats what i do with all my bumpers and sliders. Can lift up each little bit at a time and get it where you want it.

I started by finger tightening the frame bolts, both the crossmember and the side of the frame rails. Once I got it where i wanted it I tightened those, then did the wings last.

 

[OwnerCS]

Set it up on some jack stands. Thats what i do with all my bumpers and sliders. Can lift up each little bit at a time and get it where you want it.

I started by finger tightening the frame bolts, both the crossmember and the side of the frame rails. Once I got it where i wanted it I tightened those, then did the wings last.

Thank you. I have plenty of jack stands.