Clean bodied 1985 Toyota 4Runner

[Brucker]

Patrolman previously posted:

[Popsgarage]

Brucker previously posted:

[Brucker]

The last pieces that we will add while the bumper is on the vehicle are the D ring (or shackle) mounts. Not only will they provide the obvious, they also will provide a LOT of strength and rigidity to the winch tray itself. We use our mill to cut the desired thru hole size.






Smoke flared up once I reopened the coolant line (had it shut off to take a better photo):

You gotta love it when you get chips like this. Not only do you know the speeds and feeds are set right, you know there wasn't any chatter and cleanup is SO much easier.

The plates fresh out off the mill:





We didn't have the right tubing in stock for the next parts. So instead of ordering a whole stick of material and having to wait on it's delivery of next week, we decided to cut our own. We happened to have some thicker walled tubing of the same OD which we could easily modify. So we put a length into one of our lathes and went to work:

[Brucker]

With the tubing now having the correct ID, we pull it out of the lathe and part off the two pieces we need using a horizontal band saw so the lathe could get back to work on making the parts we had interrupted.





The left over section of tubing shows just how much material we needed to remove:



Then insert the tubing into the plates that were just made




And then welded them together



The hangers will be able to except the more common sizes of D rings in this industry, 5/8", 3/4", and 7/8" shackles



Now we are able to tack weld them into place

[Atl-atl]

Brucker previously posted:

[carpenle]

Band saw, lathe, mill, man I am jelioius I really like the story behind the green lathe. I have an old antique Atlas 10" Model D metal lathe, that was manufactured in 1936 and still works.

[IMG][/IMG]

[Brucker]

Popsgarage previously posted:

[Cr33p3r]

That ol green lathe is a cool piece of machinery, enjoyed checking it out when we was up there. Now I am wishing I wouldn't have sold my old Milling machine. I do need to get back up to your place soon and look at a few of the machines you built cause I need to build a couple of them for the garage.

[Brucker]

1freaky1 previously posted:

[carpenle]

Brucker previously posted:

[Brucker]

The majority of the work left on the front bumper will be done with it off of the vehicle. With it removed and sitting of the fab table, you are able to see the inner support structure better.



Our focus turns towards making the mounting plates for the flush mount lighting from Rigid Industries. We have used their products on multiple builds now and they have yet to disappoint. Some of the best lighting, if not the best, you can buy. Here is a shot from an earlier build showing what one of their 50" light bars can do:



On this bumper we will be using a set of their Dually D2 driving lights. They won't pack quite the punch as the 50" above, but should produce more than enough illumination for our needs. Here is one fresh out of the package:



We make a set of mounting plates



Then bend up some round rod to use as spacers so the lights will be truly flush with the front face of the bumper



We make the final cuts to the plates and start to fit the rod



Once the rod is welded to the plates, we smooth the edges



Added cage nuts



And test fit them into place







We then clamp the bumper to the fab table and tack weld the mounting plates and front face plate into place

[Popsgarage]

And now I understand why you made the mounting holes for the lights bigger than what you originally had made them. Looking good.

[xaza]

Very nice bumper indeed!

[Popsgarage]

Did you buy or build your table???????? 'Cause that would be a handy addition to the garage.

[The StRanger]

Sweet.

[Brucker]

xaza previously posted:

[Brucker]

Popsgarage previously posted:

[Popsgarage]

Must weigh close to 500 pounds or more, but man, would it be handy for clamping projects down and keeping them flat while welding. How long did it take you to drill and tap the top????

[Brucker]

Popsgarage previously posted:

[Popsgarage]

Mag drill would help with punching the holes for sure. I'd have to hand tap every hole though. I did look at some of the plans for the Miller, Lincoln and a few other table. Wouldn't be a hard project, just a bit time consuming. Which tapping arm do you have and what was the cost?