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. Did I make the right decision? Here it is fully welded and bolted on the truck:





Clearance between the tailgate and the outriggers is 1/2". The next step is to cut pieces to run forward to just behind the tires (for side/corner body protection) and add a hitch receiver. I plan to run the receiver through the bumper like Shawn did here. I don't plan on towing anything particulary heavy. What do you think would be the limit on towing with this? I would like to tow a sandrail on a trailer or perhaps a pair of jetskis. Ideas for reinforcement if neccessary?

Thanks for your advice! <img src="/forums/images/graemlins/cheers.gif" alt="" />