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Thread: Clean bodied 1985 Toyota 4Runner

  1. #61
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    Default Re: Clean bodied 1985 Toyota 4Runner



    Before we can start working on a front bumper, we need to strengthen the front cross member/spring hanger/frame section. To complete this we will fabricate a support plate for the area and weld it into place. This will add the needed strength as well as tie everything together neatly.

    We begin by cleaning the area in question up and taking down the high spots in the existing welds in order for the new plate to fit properly.



    We then take the necessary measurements for widths and heights and also hole placement. Then lay those out onto our material. The material we went with is 3/16" mild steel.



    Then we cut the plate into the rough shape with one of our plasma cutters.



    Cleaned up the edges and punched the through holes for the bumper mounting hardware



    Mounted the plate into position using the factory hardware for the bumper



    And then fully welded the plate into position and cleaned up our welds



    Hope to be able to start on the front bumper design and fabrication soon. The shop is still crazy busy and other projects seem to keep taking precedence. The owner also just added another couple things to the "must do" list for us this time around. More details soon :evil:

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Our client prefers plate style bumpers over most tube style bumpers. But he doesn't like what is currently available on the market (too big and bulky like the ones made by ARB). So he gave us the green light to let our creative shine and dream up and fabricate something just for him.

    Here are the few guidelines he gave us:

    -must be a plate style bumper
    -must have accommodations for some flush mount lighting
    -must offer great protection while staying close and tight
    -prefers open winch design over it being enclosed
    -Use an XRC8000 winch with synthetic line

    While trying to take everything into account, we are able to come up with a rough idea of what we are after. Though, keep in mind we are going to be creating this on the fly so things may change as we go. I will let the photos do most of the talking, but will try to highlight some areas with some more explanation. But as always, if you have any questions as to why we did something a certain way or about anything really, just ask.

    We start by designing a simple "backbone" for the bumper that will be bolted directly to the frame







    We then layout, cut, drill, and bend up a simple winch tray







    Test fitting the tray to the backbone





    We then bolt the backbone onto the 4Runner using the factory hardware




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    Default Re: Clean bodied 1985 Toyota 4Runner



    That ain't much of a bumper...

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Interesting. Looking forward to the progress. And pics. What machine do you have for a plate bender????????????

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Tack welded the tray onto the backbone





    Designed and cut the top plates for the wings



    Tack welded a couple risers and the top to each wing into place







    Then added the front plate. You notice it's odd shape as it will hold the fairlead and it has provisions cut on the sides for some flush mount LED lighting from Rigid Industries





    And a couple more plates fab'ed up and tacked into place on each side. An internal vertical support and the first pieces of the sloped section of the front face.






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    Default Re: Clean bodied 1985 Toyota 4Runner



    Now with the addition of the aluminum hawse fairlead. The front bumper is starting to take shape, though, keep in mind that we are making this one up as we go. This means you might see a few changes as we progress.



    We cut a couple pieces of angle iron for the front face then tack welded the angle into place and modified the front plate to add a slight slope upwards.











    Another set of internal vertical support plates tacked into place on each side.





    Next piece is cut and fit into place








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    Default Re: Clean bodied 1985 Toyota 4Runner



    88Toy previously posted:
    "That ain't much of a bumper..."

    Patience. Got interrupted while posting updates. More to come soon

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Popsgarage previously posted:
    "Interesting. Looking forward to the progress. And pics. What machine do you have for a plate bender????????????"

    I actually own 5 different break presses. All different styles and sizes. The bends in which you are referring to were done on the smallest setup which was put together from a kit bought from Swag Offroad.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Brucker previously posted:
    "Patience. Got interrupted while posting updates. More to come soon "

    I know. This is gonna be sweet

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Brucker previously posted:
    "I actually own 5 different break presses. All different styles and sizes. The bends in which you are referring to were done on the smallest setup which was put together from a kit bought from Swag Offroad."

    Hey, Pops, isn't that the one you pointed out a while back on a different thread? Good to see when something actually works.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Brucker previously posted:
    "a kit bought from Swag Offroad."

    I've been looking at their finger/box brake for home. Some friends had a small Piranha at their metal fab shop that I could use if needed. Sadly, they no longer have it. Loved that machine. Dimple dies, hole punches, shear and brake. The only problem with it was the fact that it'd only bend a 8" wide piece. And the brake jaw operated like a scissor, so it'd only bend a clean 90 degree.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    nice work Aaron

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Rick previously posted:
    "nice work Aaron"

    Thanks for the kind words

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Picking up from where we left off, we add the last couple of inner vertical supports to each side







    With all of the inner pieces tack welded into position, we are able to make the rest of the plates to finish out the front faces.







    The next couple of plates on both sides needed slight bends in them in order to make them fit properly






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    Default Re: Clean bodied 1985 Toyota 4Runner



    The next plates installed on both sides





    And the last set of plates for the front faces tacked into position








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    Default Re: Clean bodied 1985 Toyota 4Runner



    Popsgarage previously posted:
    "I've been looking at their finger/box brake for home. Some friends had a small Piranha at their metal fab shop that I could use if needed. Sadly, they no longer have it. Loved that machine. Dimple dies, hole punches, shear and brake. The only problem with it was the fact that it'd only bend a 8" wide piece. And the brake jaw operated like a scissor, so it'd only bend a clean 90 degree."

    The SWAG benders (and kits) are decent for what they are and the money he wants for them. They too have their limitations though. They can only bend up to a 3" section of 3/8" thick material and maxes out out 19" sections of 3/16" or thinner mild steel. And it REALLY struggles with the thicker stuff. They are also very limit as far as dies. You only get the one bottom die so you are limited with it's depth as you can not change it out. Hence the reasons behind my multiple pieces of equipment.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Man Aaron that thing has taken on a whole differrent look since I saw it last time I was up there. Looks great, like how you designed the front bumper.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    1freaky1 previously posted:
    "Man Aaron that thing has taken on a whole differrent look since I saw it last time I was up there. Looks great, like how you designed the front bumper."

    Thanks for the kind words. Was originally planning on having it done and out the door by Christmas, but with all the extras just added on, and the other projects going on, I am now hoping for early spring. And that is if the parts actually get here as scheduled, which I have learned doesn't always happen. Again, thanks for the kind words. Looking forward to seeing your new ride when it arrives.

  19. The Following Member Says Thanks to Brucker For This Post:

    Cr33p3r (December 21st, 2013)

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    Default Re: Clean bodied 1985 Toyota 4Runner



    Nice work on the bumper! Just curious what the green machine is in the background.

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    Default Re: Clean bodied 1985 Toyota 4Runner



    88Toy previously posted:
    "Hey, Pops, isn't that the one you pointed out a while back on a different thread?"

    Yep!!!!!!!

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