SFA Hilux pipe bumper

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niclemaitre
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SFA Hilux pipe bumper

Post by niclemaitre »

Hi there

So I've always disliked the SFA front bullbar and bumper they're ugly and decrease the approach angles badly so I decided to design and make my own pipe bullbar from the original bullbar.

Bumper removed:
Ak6nujPsrJGHw3wx43BgxMUIVpJhaCm4_fBINmKd9Cf_.jpg
Committed now:
AjdW_dGE_h9LvhS6ZivUfW4t_hAqetyfVs1h8hyVAT7O.jpg
Bracket design to be laser cut:
Bracket flat.jpg
Wooden mockups made from a 1:1 scale print out:
AqdC59ZwPyoyiYltlK4OTsOdi7ULvJ44fspopTBSX7hC.jpg
Wooden mock ups fitted with original top tube:
AgF4TJVFyPB6cwxO5bc9Y0WjJv6pn9J1tqsX6aYWY-OK.jpg
AmCJpl2ou0beDXOHGJuh4YY5ab3jTKC6gl-NvPKlGNlj.jpg
Putting on tabs to mount the bracket:
AldaVDSiCN9Mul5bLHG-snhdUC2WtciEsNOdeSSMcDxo.jpg
Ar_pUyBO8BCTLCusi7OzQPIMdyQSFUTgY0SgAE7H-3Tp.jpg
Checking the fit:
AnSWDrfVq1f1JjrbhDG5hMMLs_ih9HUYDHWWVXoGTmtd.jpg
New holes in the old mounting brackets:
Ah2T9YL5Ub2wOR0PGjtldi64KSshD-JBfl8a2gykBVNV.jpg
Cleaning off the last of the old welds:
Aotee2c1csNBMES0wsAD_fCbQzqTS29BDMtDaSjxN7bS.jpg
Top tube tacked in place:
AlJs3Je5b3KCJ3SKYQlzjcYbCWXZqkg3cl693JhzIRwc.jpg
Miters for the side tubes:
AtnIBCVV1bCMsd4EKkwWCltmxP3MwkxYShyKobmVV065.jpg
I found the most amazing little program to print out cutting diagrams for mitering tubes together, it's called TubeMiter.exe. You give it the OD of both tubes, the wall thickness and the angle at which they meet and it generates a paper template that you can cut out and stick onto the tube to make a cut line for the grinder. Super simple and easy. Available here: http://www.ozhpv.org.au/shed.html

Side pieces welded in place:
AsFPSpx4JbyJea6P0OmwKT8dEH5Qvf4QVXhRxl8oRSdf.jpg
Lower tube test fit:
AiGsMUpTiM7ATL7cqZ5KgMaJbYvO6JqEfgpgkON-fnbg.jpg
High lift points in the lower tube:
Aiw0QFmGS9ckUokdY0gRXYk99Y5V3s_Xqqc4NE_ncdo8.jpg
Almost finished:
Apy2AwQTbjd3CaQ6HmAkt1nB2wGClrObpgwQrhcfR2Vg.jpg
And ready to be sent for acid dipping, galvanizing and powder coating:
AtscVHBnQHp4RKNSTut2s92pArYixIR2b0WHsXNS1Ho-.jpg
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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Haboob
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Re: SFA Hilux pipe bumper

Post by Haboob »

Looking Great...
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Re: SFA Hilux pipe bumper

Post by 4x4BEES »

Stunning :thumbup: :thumbup:

Can't wait to see the finished product.
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Re: SFA Hilux pipe bumper

Post by Froll »

Looking good so far.
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mcw
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Re: SFA Hilux pipe bumper

Post by mcw »

looking good
did also made my own gives the bakkie its own look


Martin
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Re: SFA Hilux pipe bumper

Post by Mud Dog »

Looking good! :thumbup:

Now cut down the original radiator hoop a tad and mount it slightly forward facing like a stinger. Makes a nice protected area for mounting your spots and looks good as well. :winkx:
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Re: SFA Hilux pipe bumper

Post by 4x4KindaGuy »

nice work
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

Mud Dog wrote:Looking good! :thumbup:

Now cut down the original radiator hoop a tad and mount it slightly forward facing like a stinger. Makes a nice protected area for mounting your spots and looks good as well. :winkx:
No thanks, not a fan of the stinger things and for the kind of stuff I usually do it's overkill. Will be mounting LEDs on the lower tube though.
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

Dropped it off at Helderberg Galvanizing this morning
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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Re: SFA Hilux pipe bumper

Post by MOFASA »

Are you going to close in the sides and centre with mesh or something similar??

Looks awsum so far cant wait to see it fitted.
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

MOFASA wrote:Are you going to close in the sides and centre with mesh or something similar??

Looks awsum so far cant wait to see it fitted.
Thanks. Collected it from the galvanizers today and dropped it off for powder coating.

Not going to fill it with mesh, there's no point, there's just sheet metal behind it on the sides and the LEDs are going to take up all the space in the center.
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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roeland.vlok
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Re: SFA Hilux pipe bumper

Post by roeland.vlok »

Dit lyk BAD ASS!!! :thumbup:
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Re: SFA Hilux pipe bumper

Post by MOFASA »

:subscribed: :subscribed: :subscribed:
Live Life in the FAST lane....
Forget the past, Embrace the FUTURE!!!!
To 4x4 or not to 4x4 thats the question....
IT'S A JEEP :yahoo: ..... You wouldn't understand....
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Re: SFA Hilux pipe bumper

Post by ChrisF »

MOOI !!


thanks for the tip on joining two pipes and getting the cutting lines sorted :thumbup:
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

ChrisF wrote:MOOI !!


thanks for the tip on joining two pipes and getting the cutting lines sorted :thumbup:

It's a pleasure Chris. It saved me lots of time, effort and wastage. I tried to get the pipes to join correctly by cutting by eye with a test piece and it was horrible. I was close to trying to make a 3D CAD drawing of the joint and then mapping the join line onto a 2D surface but that would have been hours of work. Drawing curves onto tube is virtually impossible but with that thing it was super easy.
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

Incidentally does anyone want a SFA bumper? Not the greatest condition, one plastic side piece needs to be fastened back on (the glue perished) and the other is riveted on. Make me an offer or wait until I am actually throwing it away.
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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niclemaitre
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Re: SFA Hilux pipe bumper

Post by niclemaitre »

And it's done! I'm really happy with how it turned out.
20150910040521.jpg
20150910040511.jpg
Happy trails
Nic

SFA '97 DC - affirmatively shopped
SFA '87 DC "Rooies" - sold
IFS '99 DC "Benny"
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Re: SFA Hilux pipe bumper

Post by 4x4BEES »

Looks great :thumbup: :thumbup:
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Re: SFA Hilux pipe bumper

Post by ChrisF »

BAKGAT !!


Jy kan trots wees op jou hande werk !
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Re: SFA Hilux pipe bumper

Post by Froll »

Looks very good. :thumbup: :thumbup:
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Re: SFA Hilux pipe bumper

Post by mcw »

20140419_132843[1].jpg
Very satisfying to make your own bumper even it is done with a few choice words
looking forward to seeing the finished product
see foto of the one I built

Martin
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