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Baja/Light Tube Bumper Build

35K views 97 replies 21 participants last post by  surfkid 
#1 ·
I know not everyone likes the look of tube bumpers and I know some question their functionality but I like the way they look and Ive wanted one for my FJ for awhile.

so heres the deal, my friend has a shop with many fab tools...among those tools are a tube bender, pipe notcher, mig welder, and chop saw...all the stuff I need to build a tube bumper. Im fairly mechanical and creative but I havent done a ton of metal fab, luckily my friend has. Im designing the bumper and together we are both fabbing it up over the next week or 2 depending on how much OT we have to do at work.

where my FJ stands right now; inner wheel well fenders are chopped, plastic bumper facade and metal subframe are removed...all is ready for fab.

Fabrication will start monday after work and I will take pictures during the whole process to show our progress for anyone who cares. Im not giving away all the details but its gonna be unique and will stand out from the croud (no raw metal finish, no aluminum skid). If all goes well that is:)

pictures to come soon! hoping it will be ready for Anza on the 24th
 
#2 ·
Re: PreRunner/Tube Bumper Build

Right on, looking forward to seeing what you come up with. I myself am torn between the plate style and the tube style, my taste changes week to week. I imagine it'll end up being an impulse buy. One day I'll jump on a good deal or one that stands out at that particular time....

Or maybe I'll find your design particularly attractive and.... :: looks up pricing on DOM tubing :: :rofl:
 
#3 · (Edited)
Re: PreRunner/Tube Bumper Build

:bigthumb:
Right on, looking forward to seeing what you come up with. I myself am torn between the plate style and the tube style, my taste changes week to week. I imagine it'll end up being an impulse buy. One day I'll jump on a good deal or one that stands out at that particular time....

Or maybe I'll find your design particularly attractive and.... :: looks up pricing on DOM tubing :: :rofl:
by all means copy what I got if you like it, its probably gonna look similar to all the other tube bumpers out there anyway...im putting this up here because I havent seen too many people make their own metal fab stuff on here yet...most have friends with shops and after a few beers most can have a fairly descent bumper. I hope im not talking too soon.

the price for tubing is what did it for me. I really want a Demello plate bumper sometime because I see how its more functional than a tube bumper, looks cleaner, and is probably better in a crash...but its also $700 I dont have right now.

im sure you know how much 1 3/4" and 1 1/2" DOM or ERW cost and were kinda talking about the analogy of cost to make CD is to buying CD as to cost to make tube bumper is to cost to buy tube bumper. its a bit ridiculous but I understand business need to make money and id probably charge the same if I was in their place.

I figure its worth a shot, if I absolutely dont like it then Jason will get an order for a plate bumper
 
#9 ·
Re: PreRunner/Tube Bumper Build

You might want to keep your stock bumper BTW.

IIRC Demello's tube bumper recommends cutting up the stock bumper to close up the big gap at the top.
ive been thinking about that too but I dont know if I can get the approach angle i want by only moving the main tube out as far as the stock bumper. Ill give it a try but if it doesnt work with my design then I will just fab up another carbon piece to fill in the gap much like the front prerunner skid.

theres a lot of ugly crap that tube bumpers dont cover up, atleast my cars black and I dont need to repaint a bunch of stuff.
 
#6 ·
Re: PreRunner/Tube Bumper Build

I have my new tube bumper comin!!!! I will keep my stock bumper just for sentimental reasons but I am really pumped with my new one! It only weighs in at 110 pounds!

K
 
#12 ·
Re: PreRunner/Tube Bumper Build

I'm a huge fan of tube stuff! :D

Here's a pic of mine that a guy in Phoenix made... comes in around 50lbs.


looks nice in black. im still not sure whether or not I want a light bar. I might leave it off and add it later. 50 lbs is about what I estimated for mine.
 
#11 ·
Re: PreRunner/Tube Bumper Build

btw, im open for ideas or thoughts on what im doing, even if you think its a bad design...let me know once I start posting pics.
 
#14 ·
Re: PreRunner/Tube Bumper Build

I know not everyone likes the look of tube bumpers and I know some question their functionality but I like the way they look and Ive wanted one for my FJ for awhile.

so heres the deal, my friend has a shop with many fab tools...among those tools are a tube bender, pipe notcher, mig welder, and chop saw...all the stuff I need to build a tube bumper. Im fairly mechanical and creative but I havent done a ton of metal fab, luckily my friend has. Im designing the bumper and together we are both fabbing it up over the next week or 2 depending on how much OT we have to do at work.

where my FJ stands right now; inner wheel well fenders are chopped, plastic bumper facade and metal subframe are removed...all is ready for fab.

Fabrication will start monday after work and I will take pictures during the whole process to show our progress for anyone who cares. Im not giving away all the details but its gonna be unique and will stand out from the croud (no raw metal finish, no aluminum skid). If all goes well that is:)

pictures to come soon! hoping it will be ready for Anza on the 24th
Huh? PICS needed of that please
 
#15 ·
Re: PreRunner/Tube Bumper Build

Huh? PICS needed of that please
I dont know the correct name for them but im talking about the cheap thin plastic piece that lines the wheel well and attaches to the stock bumper. those have to be cut when you install most after market bumpers. i cut those to force myself into building the bumper.
 
#17 ·
Re: PreRunner/Tube Bumper Build

Oh yeah ok that makes sense. I removed mine entirely.
i was thinkin bout that too as these pieces are barely held on by two plastic rivet things. they will probably fall off on their own over time.
 
#18 ·
Re: PreRunner/Tube Bumper Build

here are a few pics of my FJ before the bumper build which I should be starting tomorrow.
 

Attachments

#20 ·
Re: PreRunner/Tube Bumper Build

well, the build didnt start today as I hoped to. Both myself and my friend got caught up at work and had to do a bunch of over time...atleast i get paid for it. we plan on starting wednesday now and finishing up friday.
 
#22 · (Edited)
Re: PreRunner/Tube Bumper Build

Cannot wait to see pics!!! Post em up quick!!
trust me, I cant wait to build it either, its been killing me. If it were entirely up to me it would be done by now. since im using my friends tools and shop I have to wait for him. Im the type of person that when they get a project in their head they wont eat or sleep until its done.
 
#25 ·
Re: PreRunner/Tube Bumper Build

Waiting for pics with baited breath....

Or is that "bait-breath?" :D :D :D
sorry to get everyone all riled up and then I dont even start when I said I was. I promise once I start there will be pics every step of the way.

I just hope it turns out as nice looking as Demello's new prerunner bumper:rocker:
 
#26 ·
Re: PreRunner/Tube Bumper Build

Take your time buddy!!! No stress here/ no pressure at all. Folks just get excited about a member doing something new and different! That's all.
 
#30 ·
Re: PreRunner/Tube Bumper Build

so here are a few pictures so far...more to come when the build is completed friday. once again...THIS BUMPER IS NOT YET COMPLETE! My friend Tomas owns the shop and youll see him in most of the pictures.

Tomas' incomplete race truck


plasma cutting the frame to bumper brackets


frame to bumper brackets


leveling the jack stands with the truck


top tube just after being through the tube bender


frame mount


welding the upper support, this will be well gusseted later


upper support in place


the final product for wednesday night after about 5 hours of work


still left to fab up is the side supports, lower supports for attachinf the CF skid, fab CF skid, light bar (if I decide to have one), 4 light tabs, and some minor gusseting. this work will be complete friday. estimated weight right now (upon completion) is 35 to 40 lbs, its gonna be light!!!

I promise I will post some better daylight photos friday.
 
#31 ·
Re: PreRunner/Tube Bumper Build

can you get a pic looking down from the top?
 
#32 ·
Re: PreRunner/Tube Bumper Build

can you get a pic looking down from the top?
ya sure, the main tube follows the contour of the stock original bumper plastic. im reusing the plastic piece to fill in the ugly gap.
 
#35 ·
Re: PreRunner/Tube Bumper Build

It's coming along nicely...can't wait to see the finished product. Do you plan on adding a winch mount?
no winch mount for me...I want to keep it as light as possible. plus thats what I have all the 4x4 guys for, to help me out if I get stuck ;)
 
#36 ·
Re: PreRunner/Tube Bumper Build

well, final build starts tomorrow afternoon. I wasnt able to get the full day off but we should still have plenty of time.

more pictures should be posted friday evening.
 
#37 ·
Re: PreRunner/Tube Bumper Build

here are some more pics of the bumper as of saturday. We still need to make the skid plate, weld on the skid plate mounting tabs, and maybe add some gussets.

lower support in place, this took forever to get right.






Light tab


side support


we had a bit of a problem when the final welds on the lower skid supports made the main supports get pulled inboard about half an inch. just enough to make the bumper not fit. nothing a high lift couldnt solve ;)


more to come
 
#40 ·
Re: PreRunner/Tube Bumper Build

It's looking great! You are already waaaaay ahead of me... :lol: :cheers:
thanks, I appreciate the complement...it was a tiring but fun process. Tomas already wants to build more FJ stuff..some things on the list are trailing arms (rear LCA), roof rack, and rock rails.
 
#39 · (Edited)
Re: PreRunner/Tube Bumper Build

the money shot




its dirty cuz right after we finished the build Tomas, Josh (zoshyii), and myself decided it was a good idea to go out to the desert at about 12 am. we went by plaster city and then el centro. my new kragen HIDs worked great and so did the bumper. we hit some pretty nice washes and big sand dunes (much like pismo). we ended up stopping our offroad adventure at about 4:30 am and decided it was a good idea to get some rest before driving back at about 9am.

This project took about 20 hours between 2 people

skid plate and paint will be added next weekend.
 
#50 ·
Re: PreRunner/Tube Bumper Build

the money shot




its dirty cuz right after we finished the build Tomas, Josh (zoshyii), and myself decided it was a good idea to go out to the desert at about 12 am. we went by plaster city and then el centro. my new kragen HIDs worked great and so did the bumper. we hit some pretty nice washes and big sand dunes (much like pismo). we ended up stopping our offroad adventure at about 4:30 am and decided it was a good idea to get some rest before driving back at about 9am.

btw, we are planning to make a few of these bumpers and sell them if anyone shows interest. this project took about 20 hours between 2 people and were looking to sell a bumper for about $500. thats less than half the price of what other shops charge (for this type of bumper). im not saying those other bumpers arent worth their asking price, its just that weve only made 1 so far and I wouldnt feel right trying to say we are professionals at building FJ parts and sell it for what others are asking. were not tryin gto make a business, just make a few parts here and there to support our addictions. a light bar can be added for no extra cost or any other minor modification. PM me if you are seriously interested, as we may only make one more. we can meet up in San Diego or LA area to discuss. let me know if you want more detailed pictures of something.

skid plate and paint will be added next weekend.

To advertise or want other members to pay for your stuff, please PM Dragon to get into the vendor market.

Thanks,

K
 
#44 · (Edited)
Re: PreRunner/Tube Bumper Build

Looks good, I may have to hit you up for a rack idea in a few months.
no problem...zoshyii is looking into one also...once we make one the second one is a lot easier to make.
 
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