my 1st gen 4runner rear bumper build

[havik]

My initial idea was to build a bumper with a removable center section so I can run a summer bumper for the harder trails and a winter bumper for snow runs or mild wheeling.
Now I plan on only running the summer set up with a pickup tailgate and high clearence rear bumper

[havik]

my first design I drew while bored at work

[havik]

I built the center section first about a year ago.
Then had the side sections bent out of DOM
I used some 2x4, zip ties and bungies to get it into place.
If i dont have a beer or two I waaaaaaaaaaaaaaay over think my projects

[havik]

Janky Jig

[havik]

one side done

[havik]

dome cap slugs

[havik]

sub frame leg welded

rear legs are welded
front legs are bolted

[havik]

I like the way it turned out
its probably a little over built/ too heavy for what it is

[havik]

center section is bolted to a rear x member
when I lifted it with a fork lift it didnt move at all.

[txlonghorn]

Looks great. I like it. I am planning on going with a pickup tailgate and chopping the rear quarters just like you did. How did you weld up the rear quarters and chop your rear fenders? Mind showing some pics of how you did it? I am new to body work and trying to figure out if I need to cut and bend a flange into the rear quarters, or what the best way to do it would be. Thanks.

[daniresch]

Agreed, looks really good! 4runner is also looking great with how you clearanced the rear wheel well. Have you checked if the rear tire rubs on the new bumper in the corner as the wheel travels up? typically a common spot. keep it up

[havik]

before i took it offroad i thought to myself that the work was not worth the work. it would have been much easier and faster to just buy a bumper and bolt it on but after being out on the rocks it is nice not dragging my ass over every single rock.

i dont have pics on my new phone of how i did it but i can do my best at describing it. if i can find the pics i will post em up here.

first i drew the lines i wanted using a 90* elbow and measured 3" and set a sharpie in place
traced the 3" line on all fenders
used a harbor freight electric die grinder 3" wheel
used poster board to stencil out the inner fenders and rear quarters
paper onto steel
lots of little magnets to hold the steel in place as i bent, grided and fit each piece into place
tacked each piece in
lots and lots of tacks
grinded as smooth as my patients would allow
primed and painted (still need paint)
didnt use any bondo yet

[havik]

at full stuff no rub
the goal this weekend is to finish my rear bump set up

[txlonghorn]

Awesome, thanks for the info.

[T-YotaFreak]

That is a sweet 4Runner!

[havik]

thanks guys

[19954Runner]

  awesome skills.

[CHansen]

Nice 4 runner! reminds me of my first car ever. A red 86 4runner. Same roll bar in the back.