Broken front bumper mount

So I've got a DV-8 bumper that I've not been super happy with, however I've just been making it work. I have gotten yanked out of messes and used my winch at least a dozen times since I've had it mounted on there. The bumper itself it two pieces and the part mounted to the frame has always been stout, however the front part of the bumper, the bolts would loosen occasionally and it would sag.

I was getting ready last night to go out into the snow today and noticed the bumper was sagging again, so I went in to tighten up the bolts and realized I have broken the front mounts. One has already let go, the other one is cracked about 1/2 way, I was basically riding on borrowed time.

I was going to just cut them off, weld a new plate onto the front, box it in on the top and bottom, and then just put the bumper back on however before I start cutting (and fucking) things up, I thought I would see what the fine folks on here thought.

Options?

 

A lot of people weld on plates like your thinking with gussets to strengthen. You’re on the right track. It’s def a weak point considering how we use it. Do you have any additional braces or just the front mounts? A lot of bumpers will sell you a brace to help keep it on.

 

Unfortunately no. I didn't know what I was doing and just went for one of the cheapest bumpers I could fit a light and winch, and I believe I have gotten what I paid for. It just bolted straight to the factory mounts, using the existing bolts and nuts. In hindsight, I think it was meant to be more decorative than functional, as it's taken some work to get it functional.

 

Maybe the RCI or C4 fab support mounts can fix that issue. Good Luck PaL

 

That’s exactly the problem with the low end bumpers.

 

After market bumpers are garbage, Chinese steel. Only actual after market bumper is ARB Bumper. ( Which is why, Toyota actually does use it on 4th gen tacoma )

I would sandblast that rust off before it spreads inside the frame.

Even the other side seems to be cracking up.. Unsafe to mount anything on that.

Take it to welder and see what they say, they will need to cut that off I am sure, because of cracks

 

Unfortunately when I started off with this truck, I had more money than sense

 

Yeah, I'm going to replace both sides, the side that hasn't completely broken off so far is cracked halfway down. I'm just glad I found this in the garage instead of staring at my bumper laying on the ground out on the trail.

 

There are various frame to bumper reinforcements. The picture is BAMF

 

War fab sells a front end chop kit that includes a new frame horn plate plus additional plating/gussets to really beef up the front end mounting, looks like its exactly what you need.

https://warfabarmor.com/collections/skids/products/front-chop-kit

 

This is my recommendation for anyone with a front bumper/winch set up.

https://overlandoutfitters.ca/produ...reinforcement-kit?_pos=1&_sid=1f6bff504&_ss=r

 

Pretty sure you mentioned about welding, at least you have that ability and skill to make it better!

 

In addition to replacing the cracked plates, maybe you could modify the bumper to mount the way I designed my 2nd gen hidden winch mount. I cut the holes in the frame horn plates to accept a steel tab to the inside of the tube frame, with a 5/8” bolt into that tab through the existing hole in the frame.

The first pic and fourth pic here show what I mean, look closely for the bolt in the fourth pic:

https://www.tacomaworld.com/threads/landphil-05-11-hidden-winch-mount.354527/

 

https://www.youtube.com/watch?v=ggUy0s6Kmnw&ab_channel=OverlandOutfitters

 

Trail boss approved. Am I right @WormSquirts lmao

 

That looks amazing! Definitely a lot to chew on there, I am certainly going to borrow some of your ideas. I especially like the stealth D-rings and the additional braces underneath. Fantastic job!

 

It quickly became clear, either learn to weld or go broke. I don't know what I'm doing so I've broken a lot of stuff. I'm not sure about skill and ability, but I've certainly got a welder and lack of caution!

 

Great to see the clear pictures of the failure. I’ve seen many bumper mounts bent but not broken.
Before I did my winch work I found this company’s solution:
https://www.rockhoundoffroad.com/product-page/tacoma-bumper-reinforcement-bracket-16-current
I used this as inspiration for my mount replacement, however if I were to do it again I would go the route it the link first brought up in post #11:
https://overlandoutfitters.ca/produ...reinforcement-kit?_pos=1&_sid=1f6bff504&_ss=r

My pictures: my material is 1/4”.

 

Damn, that thing is stout! I've gotten the mounts replaced at this point and the paint is drying. I ended up ordering a set of the RCI braces, which I hope will get me a little further down the road. If this breaks, I am certainly going with your setup.

 

Doesn't seem too difficult. The best advise is going to come from reposting this question in "anything welding".

https://www.tacomaworld.com/threads/anything-welding.113957/