Frame modification and rear bumper build - TTORA Forum
 
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post #1 of 26 (permalink) Old 12-27-2009, 09:09 PM Thread Starter
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Frame modification and rear bumper build

When I bought my truck this summer it had no rear bumper on it. After further examination I found that to be for a good reason. The truck had been rear ended by someone which bend the rear section of the frame down, and the last 2 bolts holing the bed to the frame were missing. It was enough of a bend that a bumper would not bolt up. Since I am down in Texas for the holidays, I wanted something to do so I decided to fix the frame and build a beefy rear bumper! This thread will be updated as I progress!

I used 4" C channel to fab all of this since it was available at my uncles shop and it fit perfectly around the frame!

You can see by the first pic how bent the rear of the frame is...


Here is a pic of one side torched off behind the shackle mount.


That is the pieces I had to cut and fab to make the frame the same length as before. This will allow me to move my shackle mounts when I do my Chevy leaf spring conversion, and will be A LOT stronger than the stock one.











Here are both sides welded up.



Here is the rear crossmember I welded in for some added support.



Arc welding upside down is no fun at all!











More to come as I get more time to work on the bumper! My design is kindof like the warn rear bumpers but mine will wrap around the sides and be supported to the frame, and have a small tube hoop up the side.

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #2 of 26 (permalink) Old 12-27-2009, 09:23 PM
ike
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looks good.




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post #3 of 26 (permalink) Old 12-27-2009, 09:47 PM Thread Starter
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Thanks! Bottom welds don't look amazing, but I didnt get around to grinding them, but they are strong!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #4 of 26 (permalink) Old 12-27-2009, 09:53 PM
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you have enough weld lenght on the other sides that it should be more than strong enough.




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post #5 of 26 (permalink) Old 12-27-2009, 10:17 PM
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Actually, it doesn't appear there is much weld surface at all between the new section and the old - or am I missing something?

Looks to me that there is just the one weld around the end. In a dynamic recovery, I would want more than that. Can you put a couple grade 8 bolts through it, so you would have the shear force to help?

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post #6 of 26 (permalink) Old 12-28-2009, 08:02 AM Thread Starter
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The outside piece of C channel is welded to the frame on the inside and outside in every place possible to weld. It is very strong! The inside piece was mainly welded to the first piece of channel , seaming them together, but beads were ran lengthwise on the inside of the box as well as the outside. There were a few spots where the inside piece was welded to the actualy frame.I will be putting grade 8 bolts through for the bumper. I should have shown more pictures of all the welds that were used to hold them on, but it is solid!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #7 of 26 (permalink) Old 12-28-2009, 08:42 AM
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looks good....glad to see we have people that can still weld the "olefasshin" way, hurry up with the bumper

Built not bought!!!
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post #8 of 26 (permalink) Old 12-28-2009, 09:34 AM
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Quote:
Originally Posted by minerdude1 View Post
The outside piece of C channel is welded to the frame on the inside and outside in every place possible to weld.
Ahh - OK. That's how I would have done it too!

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post #9 of 26 (permalink) Old 12-28-2009, 09:41 AM
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only real way to get more weld would have been to drill holes in the side of the frame extension and then weld to the frame by those holes as well.




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post #10 of 26 (permalink) Old 12-28-2009, 12:12 PM Thread Starter
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Quote:
Originally Posted by ike View Post
only real way to get more weld would have been to drill holes in the side of the frame extension and then weld to the frame by those holes as well.
And I did debate that! I waited till I got everything else welded to see how sturdy it was and decided I didnt need them. I wanted something strong enough to attach a bumper to AND support the new shackle mounts I will be putting on later down the road.

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #11 of 26 (permalink) Old 12-30-2009, 11:39 PM Thread Starter
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Did a little bit of work on the bumper tonight... I forgot my camera, so pics will come hopefully tomorrow. I got my design idea from one of my offroading magazines. I am building a "shell" or skeleton out of 3/16 steel rod. This will give me something to trace my panels onto a sheet of plate steel I have, and be able to build more bumpers off of my skeleton bumper. So far it is looking pretty sweet!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #12 of 26 (permalink) Old 01-01-2010, 12:44 AM Thread Starter
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Did some more work on the bumper "skeleton" today and here are the pics. I have the skeleton completely done now just have to trace each plane onto the plate steel and cut them out! This template also allows me to make more of these bumpers in case anyone on here likes them and wants one.










1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #13 of 26 (permalink) Old 01-01-2010, 06:43 AM
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That skeleton is looking good! If this were my project I would just cut the bed sides and have that wrap around piece go underneath the bed instead of wrapping around the outside of it. But this just my personal preference.

Can't wait to see the finished project!

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post #14 of 26 (permalink) Old 01-01-2010, 08:58 AM Thread Starter
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Thanks! It will be attached under the side of the bed also. Those side pieces will have a tubular hoop going up to help protect the sides of the bed also.

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #15 of 26 (permalink) Old 01-01-2010, 09:32 AM
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Be sure to plate across the bottom too - you don't want the back edge of the bumper to hang up on something when you come off an obstacle. At an angle wuold be nice, to help it slide.

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post #16 of 26 (permalink) Old 01-01-2010, 09:58 AM Thread Starter
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In the picture of me holding the skeleton, you can see I did add in some bracing. It is 3" thick to add some bracing. I am also going to add triangular gussetts when I build the actual bumper.

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #17 of 26 (permalink) Old 01-01-2010, 03:09 PM
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looking good. That wire template/model is a great idea.




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post #18 of 26 (permalink) Old 01-01-2010, 10:40 PM
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Is that skeleton going to make its way into the finished product or is it purely for mockup purposes? Neat idea either way.

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post #19 of 26 (permalink) Old 01-02-2010, 03:56 PM Thread Starter
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I used the skeleton to trace each "plane" of the bumper onto a sheet of plate steel. I have all the pieces traced out and cut, and am working on assembly of it now! I need to upload the pictures of it!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #20 of 26 (permalink) Old 01-07-2010, 04:51 PM Thread Starter
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Got some more done the other night... I have everything cut out and all the edges cleaned up. I have 6 pieces welded together right now and should have it all done tonight! Here are pics of everything except what I did today.





1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #21 of 26 (permalink) Old 01-07-2010, 11:32 PM Thread Starter
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Here is the current state of the bumper... I got this far and started on the brackets that will hold it on. I got the holes drilled in the frame and got the mounting plates cut and holes drilled in them too.


1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #22 of 26 (permalink) Old 01-07-2010, 11:36 PM
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That thing looks great. keep up the great work.




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post #23 of 26 (permalink) Old 01-07-2010, 11:47 PM Thread Starter
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Quote:
Originally Posted by ike View Post
That thing looks great. keep up the great work.
Thanks! I still have to weld on a couple more pieces, and then go over and clean up all the welds and flush everything up. When you trace pieces and cut them with a oxy torch, the lines never come out perfect. I am very pleased with how it has turned out so far though!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #24 of 26 (permalink) Old 01-10-2010, 08:01 PM Thread Starter
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Ok since my time in Texas was done yesterday, I had to get the bumper mounted for transport! I have not completely finished it yet, still need a little more welding and clean up the other welds. But here is what it looks like on my truck now!


1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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post #25 of 26 (permalink) Old 01-11-2010, 08:37 PM
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looking good man!! I might have a plazma cutter here soon if you need help with the front let me know!

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post #26 of 26 (permalink) Old 01-15-2010, 10:25 AM Thread Starter
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Thanks Jay! I still haven't gotten around to working more on my bumper because of school and working so much this week/weekend. I will post more pics up once I do some more!

1989 ex cab Yota pickup
-3.4 swap, dual cases
-SAS
-35" BFG KM2 tires
-custom rear plate bumper
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