It took a lot of sketching and resketching, but I finally came up with this design.



After holding up some scrap pieces of bent tubing to the truck and scratching my head, I decided it would be worth spending some time in Photo Shop to see if I would like the design. Here is my 4Runner with a PhotoChopped bobb, paint job, and minimalistic exocage.



Okay, I like it! Time to get to work. The next step was a lot of careful measuring. I sketched out front, side, and top views of the key points on my 4Runner. Then I took lots of measurements and drew in circles to remind myself to offset to account for the tube. Next, I transfered my key points into Bend Tech Pro. Gotta be careful here and double check all points.



There are a few different ways to make parts in Bend Tech Pro. I like to get all my pick points figured out, then connect the dots. You can also make each piece individually in EZ3D and then couple them together.



Here's what it looks like using 1-3/4" tubing and a 6" CLR. What better color than yellow?





There are two pieces with four bends. The very uppermost piece (number 6 below) is a multi-plane part with four bends. It's hard to see but there are some smaller bends just outside of the two middle bars. I circled them in red.



I don't have a notcher and since I have NO EXPERIENCE with tubing, I'm going to rely heavily on Bend Tech Pro's tube coping feature.



This will be my FIRST TIME ever bending tube to make something useful and I will be using my recently completed numerically controlled hydraulic tube bender! Here's a shot of me next to the bender:



And here is a video of it in action with my girlfriend at the wheel: CLICK HERE FOR VIDEO
There is a VERY DETAILED writeup with hundreds of pictures here if you are interested: http://www.extremefabricator.com/BB/viewtopic.php?t=8

Today I got the first few pieces bent for the bumper. Here's my plane of bend bracket, which was custom made by John (aka CaptainFab) on www.offroadfabnet.com. John has been following my progress on the bender and offered to make this for me to save time. He even custom powdercoated it yellow (the future color of the bender) and added a knurled setscrew. THANKS JOHN!



(below) The first piece I made was the lower hoop. This came out perfect, but I ran into a bug with the cutting templates (now worked out) and will have to cut it for fit tomorrow.

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper9.jpg[/img]

(below) Here I am measuring to check the angle. I didn't have to rebend a single piece today; springback was consistent from tube-to-tube and the bender nailed every angle. Bend Tech Pro worked awesome!

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper10.jpg[/img]

(below) The next part is the waistline hoop. This is a four bend, single plane part. Here I am gearing up for bend number 2.

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper11.jpg[/img]

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper12.jpg[/img]

(below) The completed part, ready to remove from the bender.

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper13.jpg[/img]

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper14.jpg[/img]

(below) I did this work today by myself, so I didn't have anyone to hold it up to the truck to check fit.

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper15.jpg[/img]

(below) Later in the evening one of my roommates got home. I had him hold the part up while I took pictures. It sticks out a little further than I had pictured, but the measurements are correct and it should accomodate a winch without moving the A/C condensor.

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper16.jpg[/img]

[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper17.jpg[/img]

I'll do my best to keep this thread updated with progress for those that are interested. Tell me what you think!

Wow, awesome tech! Definitely keep it coming. I appreciate that you are designing a bumper that is different from anything else out there.

I think you consistently stay ahead of the curve. No pun intended.

Way to go, man.

I also think that you can sell those bumpers. Like Harry said, not like anybody elses....

Thanks guys! <img src="/forums/images/graemlins/smile.gif" alt="" /> I was trying to make something a little different, although it's hard to deviate very far from the standard bumper designs. I didn't want a stinger, so I had a chance to do something a litle different.

As for producing/selling these, I don't think I would have the time to do it. Bending the tube would go very quickly, but cutting/coping, fitting, and welding takes time. We'll see how I do on my first time out. <img src="/forums/images/graemlins/cheers.gif" alt="" />

I'm going to do some more tonight.

Here's one...how bout you sell pre-bent kits? The buyer can cope and weld. I would....

More power to ya.

nice Very NICE!!!
I read your write up on Pirate. Good to see your doing something with it. I am speechless.
Rock on Dude!!!
Mike

Looks good. Nice job on the bender. What type of dies are you using!!!!

Looks Nice.

Sweet bender too. I used a harbor freight special....not exactly high accuracy...but it did the job.

The cutting and fitting was the worst part. I over cut one of my tubes and had to redo it....what a pain in the arse.

I've got a brother in-law who's a fabricator....after doing my front bumper and sliders, I have a new found respect for that kind of work.

Congrats! x2, you should offer a weld-your-own, pre-bend tubing service. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Thanks all!

MnMsToY - Thanks! Too flattering..

OOP'S - Thanks for the comlements. I am using a mildly modified (remachined by me) Pro Tools 105 die, 1-3/4 x 6" CLR.

CORunner93 - Thanks! You are definitely right about all the fitting. It sure is a pain! The bending was a cinch.

Tex & allochris, I think a pre bent kit would be pretty easy to do. I would consider making a copy if someone contacted me requesting it.

UPDATE

After getting a little more familiar with Bend Tech's cutting features, I spent most of my evening cutting tube. I started with the lower hoop which needed to be fitted to the frame.



I suppose I could have cut it in a chopsaw, but I figured I would be less likely to screw up using a cutoff wheel.



It fits perfectly as designed!



Bend Tech prints out these neat wrappers for coping tube. I'm finding them to be quite handy! For pieces that are fishmouthed at both ends, you have to line them up somehow, so I initially used my table to do the job.



Then I found it was a lot eaiser to use a piece of angle iron.



(below) Here is an example of a short piece with fishmouths on both ends. You can see the lines printed on the wrappers for lining them up. One thing to keep in mind if you are using these is to cope the tube so your seam wont be visible on the final part.



(below) It takes quite a bit of time using a cutoff wheel! I really need to get a hole saw type notcher - these would go much faster.



(below) Since the tubing has some thickness, you can't just cut along the wrapper line and expect it to fit. It takes a little grinding on the inside to get things right.



(below) After a while I started getting a feel for what areas needed grinding to get a nice fit.



(below) No less than four hours later cutting and hand notching parts, here is where I left things for the night.



[img]http://thebandit.xtremefabricator.com/frontbumper/frontbumper28.jpg[/img]