DIY Aluminum bumpers

Hello all.

I drive a 2015 4 door Tacoma and
I’ve been getting my truck into rougher and rougher places over the last few hunting seasons (because it can) and I’ve finally decided it’s time to get into a winch front bumper and maybe tire carrier swing out rear bumper. I need them to be economical and made from aluminum as I carry a pretty full payload a lot of the time and weight is an issue.

I have looked at many options and another taco buddy suggested Pilfrybilt but we all know that story. Pre fabricated units seem over priced so I’ve started looking for a decent DIY setup. I have access to a professional welding shop (and instructor) so this seems like a good way to go. Does anyone have any suggestions please?

Must haves:
Aluminum
Strength
Winch mount
Fog lamp cutouts

Would likes:
LED light bar capable
Headlight and grill loops
Skid plate

Thanks in advance for all your sagely advice.
Cheers.

 

https://www.coastaloffroad.com/?v=7516fd43adaa

Check out this site. They have a few different ones and offer aluminum.

 

Thanks these look great but the $850 extra cost to change from steel to aluminum is a bit steep. Cheers.

 

Are you looking for CAD files to make your own (you intend to do all the welding and have the metal cut) or are you looking for a vendor that makes aluminum bumpers that you'll buy bare metal or powder coated and install yourself?

 

Sticky taco,

I could certainly work with the CAD files however a pre cut kit that I can weld myself would be ideal.

Cheers.

 

Whatstcp,

I understand that aluminum is expensive as a base material but 135% price increase doesn’t make sense to me. I’m aware of the need for suspension upgrade and have that in the works but when you’re packing a weeks worth of cold weather equipment and food and a wee boat and a couple of other blokes, every lb counts so I’m trying to work out the best and cheapest route for optimum performance.

Didn’t think of the battery upgrade for the winch though so thanks for the heads up there.

I’ll shoot Coastal an email and see if they can work with me a bit.

Cheers for all the advice. It’s a lot more complex than I thought.

 

Personally wouldn't trust a rear swingout bumper made of aluminum. I'm even hesitant on steel ones when one is asking to carry a 34"+ tire, fuel cans, ... then take it off road.

 

I want CAD Files......

 

If you want strength, go with steel especally for housing a winch. Sure Aluminum is lighter but it has an elastic modulus that is 2/3 less than that of steel, meaning for the same strength as a steel counter part, you would need 2/3 more material. Also, the welded joints of aluminum are much weaker than that of steel. In order to regain strength of an aluminum joint that is welded, it needs to be heat treated.

If you are concerned about weight, have you looked into stiffer suspension packages or even gears?