Rectangular tube bumper with fold down Hi-Lift carrier

[xtremefabricator]

This was my first fab experience. Pardon me for copy & pasting this from a really old forum thread.

---Originally Posted 4/18/04---

After buying a chopsaw and borrowing my brother's MIG, I finally started building the bumper for my '86 'Runner. Here we go...



I started with the brackets. These are 3in channel (.250 thick) cut at an angle to go into the frame, then drilled and tapped for 1/2"-13 bolts (probably will add nuts) and adorned with 0.250 plate for the drop down.





After much measuring and cutting, I tacked up the main structure. This is 2x4 box tubing, 1/8" thick. I decided against a bulletproof 3/16" tubing based on weight. Here it is fully welded and bolted on the truck:





Clearance between the tailgate and the outriggers is 1/2".

---Originally Posted 10/14/05---

Here's what I made to hold my HiLift











I did circles around my truck trying to think of a place to mount the HiLift, but came up empty handed. I haven't built a front bumper and this is too long to fit inside and still have two passengers in the back. So I mounted it as shown to the 2x4 bumper car bumper that I built a couple years ago.

I used 1.25" square tubing for the H frame that the lift will mount to and made hinges out of 1.5" 1/8 wall square tubing. The smaller tubing fits perfectly inside the larger stuff. The hinge points are 3/8" bolts w/ nylon lock nuts. I found some pins at Home Depot to hold it in the up position which I will eventaully chain to the H frame so they don't get lost.

I plan on welding a few bolts in place with wingnuts to hold the jack on (the picture just shows some bolts and nuts I had lying around).

Total cost: $10 in hardware and leftover material from when I built my [URL="http://www.pirate4x4.com/forum/showthread.php?t=345772"]rock sliders[/URL].

This isn't a permanent solution. When I build my cage, I plan to mount it up top. But for now it should work well and still allows the tailgate to drop.

--- Originally Posted 12/2/05---

Here's what it looked like a year ago when I made it. Looks like a bumper car if you ask me.



The original plan was to mitre cut some more tube to extend forward at the corners. I cut the pieces to do it, held them in place, stood back, vomitted, and never looked back:barf: . Later I saw this done on other people's trucks and hated it. So I finally got around to doing this.















I'll get some pics of it on the truck tomorrow. Looks a lot better I think. I am going to leave the ends uncapped so I can still use the hi-lift there.

*EDIT* Here's a picture of it on the truck. There are more later in the post.


I just needed something to get my mind off finals next week and this little hack job was just the right project.
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[G-Rider]

I think you need to build a trick new rear bumper to match the front ..It looks like you will drag that jack on rocks like that..