That bumper is looking great.

I use one of those tubing notchers from Harbor Freight in my drill press. It works pretty well. I have found that if I use a hole saw that is 1/8th inch bigger then the tube they seen to fit better with less grinding.

Keep up the good work and that bender you built blows me away!!!!!

Looks like a great setup you have there, I am jealous of the bender. Obviously engineering isnt a problem for you, but maybe a drawing class is in your future? <img src="/forums/images/graemlins/smile.gif" alt="" />

Thanks guys!

I will take that drawing class ASAP.

UPDATE

It may not seem like I did much since last time, but it took me about an hour to tack these together. I'm sure more experienced folks wouldn't have taken nearly as long, but I took a ton of measurements and did a lot of creative "fixturing" using things laying around the garage to get all my angles right. I also did a little grinding here and there to get better fits on my notches. So although it doesn't look much different from where I left off yesterday, all this lower half needs now is finish welding. Here it is loosely attached to the truck (using bailing wire)





Do you think there will be enough room for a winch? I left about 8" in front of the radiator to work with.



Here is one area I would do differently a second time around. I am not happy with how much space there is between the marker light and the bend at the corner. If I moved the bend apex toward the rear of the truck this area would look much better.



It doesn't look too bad from this angle.



Here's what it will do for my approach angle. What do you think? Liveable?



33s and IFS



My next step will be making the plate for the front of the crossmember (that should be pretty quick/easy) then I will get started on the upper assembly.

WHY WAS THIS REMOVED FROM THE EARLY TOYOTA TRUCKS FORUM??? An '86 doesn't qualify as early? <img src="/forums/images/graemlins/scared.gif" alt="" />

I see allen being a fixture in a couple of you pictures.

Who's your advisor for your senior project?

Yeah he was trying to show off his unhuman strength.

Jim Widmann is my SP advisor.

Looks great! Cool software.

Agree... that your '86 belongs here in the Early Toyota Forum.. Sooo moved... <img src="/forums/images/graemlins/cheers.gif" alt="" />

The trick to those outter bends near the corners is to not make them 90 degrees. I think mine are more like 75 or 80 degrees. I kind of stumbled into the right angle for mine, simply due to the fact that my bender wouldn't do a 90 degree bend without kinking the pipe. I stopped as soon as I saw it kinking (and thinking I was going to have to start over), and as luck would have it, it was a perfect fit. Once it comes around the corner near the light the outter edge cuts almost perfectly around the light and extends to the outter edge of the flared part of the fender...with about 3/4 of the pipe extending out from underneath the fender.

wow, that looks good & simple!

Will you have 2 side tubes from frame to each ends of the main tube for side reinforcement?

How about cutting some 3/16" stainless plates to fill the 2 empty holes at the front (except the middle hole for winch) for increase look & air flow?

Looking great dude. Oh and welcome back to the Early Toyota board <img src="/forums/images/graemlins/smile.gif" alt="" /> I'm looking forward to the final product <img src="/forums/images/graemlins/kewl.gif" alt="" />