DeMello FJ Cruiser Bumper R&R

[Brody]

I bought the damaged DeMello FJ Cruiser front bumper from Khal and am in the process of repairing it. I cut off the damaged section and made templates out of the same thickness steel. I then carefully welded these pieces back in and fully welded them on both sides, rather than stitch weld them as DeMello did. These sections are now as strong or stronger than the section I replaced. I replaced the bent section on the back side on top by the winch and also added a 1/4" x1" stiffener on this part. My though being that this wouldn't have even bent had the stiffener been there. I have a little fine tuning to do today and when I am finished with that, I am going to add a couple more crucial (to me) gussets to what is already there, finish sanding it, primer it, and then paint it with a durable truck bed liner paint. It is then going to be ready for resale.

I'll post the finished pictures and price when I am done.

[Brody]

Here are the next six pictures:

[Brody]

And the last pre paint and gusset pictures. The final pictures will follow later today.

[Mporter]

Dang Pete, gonna sell that and make a huge profit? Or just keep it for a future rig ;)

[Brody]

Dang Pete, gonna sell that and make a huge profit? Or just keep it for a future rig ;)

I don't think there is such a thing as a huge profit in the fabrication biz:D:D...ask anyone who does it...

I took the $$ out of the island vacation funds to buy this, so it is going to be up for resale as soon as it is painted.

I have the rig I am going to keep for awhile. All I have to do is fine tune it a bit: wire in the Split Second Piggy Back ECU, get a trick overbored racing throttle body, install a set of Johnny Joint style rear shackles, do a rear disc brake conversion, raise the transfer case so I can do a flat bottom...you know...all the neat crap that can be done after all the basic stuff is in place. Too bad it all coats $$.....

[JeffX]

That's beautiful. That'll be a great buy for somebody. You should use some scrap to make youself an FJ front end jig so you can offer custom FJ bumpers in the future.

[Brody]

Thanks. I did an Fj jig when I was working on this! Sean and both make bumpers anyway, usually custom and we do make templates of bumpers we design and make, for any rig.

[Brody]

Here are the pictures of the additional strengthening ribs, gussets and inside corner braces I did as well as the final finished product. With the addition of the braces, especially the strengthening rib that spans the back of the top and the inside corner braces, this bumper is quite a bit stronger than the original design.

[Rob]

Looks great, Pete. If I didn't already have a bumper on the FJC...

[Chris]

Well done Pete, that sucker looks heavy! Any idea what it weighs?

[RockyMtnHigh]

Damn nice job!!! :thunb: Now I know where to take mine should I ever kink the crap out of it!

[Brody]

Thanks! Try not to as much as I would like the work! I was just very glad that no one got hurt in the accident that caused the damage. I don't want to think about what kind of damage there might have been with the stock plastic junk on his rig!

[A-TRAC]

Very nice Pete. You need to show the body shop my FJC is at these pictures. The insurance folks could have saved themself some $$ by asking you to repair the old bumper instead of paying for a new one.

[WINKY]

impressive pete!

(i need a welder)

[Mporter]

well done, looks great.

[Brody]

Thanks Khal! I sent the pictures/link to Shain, the guy with the white built up 4Runner. When I was picking up your bumper there, he was looking at my heap and we were talking about some bumpers and sliders that he wants to do on it.

[A-TRAC]

Any idea what it weighs?

Without the metal that Pete added, it's supposed be around 80 lbs. It's one of the lighter plate bumpers for the FJC. The ARB is around 150 lbs.

[Brody]

Well done Pete, that sucker looks heavy! Any idea what it weighs?

Thanks Rob and Matt! I always try to do work on someone (or soon to be someone's) elses stuff like I would do it on mine...probably better actually cause their stuff is usually better looking than mine to begin with....

DeMello has it listed as weighing 84 pounds. If it isn't right at 84 pounds, it is very close to it. I probably added another pound or so. The whole center section, winch plate, and mounting points are 1/4" with heavier gauge used on the two points with the 3 holes on each side. Everything else is 1/8" except for the inner light mounts which also act as a brace and these are also 1/4". Pretty stout piece of work. More bulky and awkward than really heavy and it is set up much like the ARB where you install a winch, then install the bumper, making a bumper installation an interesting proposition, at least for one person.

[A-TRAC]

You can make some cash off of this stuff Pete. Ever considered going big and doing it full-time-ish?

I know Armorology down in the Springs has a wait list 6 months out. He has no jigs, so you have to leave your vehicle with him for weeks while he builds you a bumper and I think the front bumper he did for the FJC was well over $2500 (I think......Joe/Jock correct me if I am wrong).

[Mporter]

Thanks Rob and Matt! I always try to do work on someone (or soon to be someone's) elses stuff like I would do it on mine...probably better actually cause their stuff is usually better looking than mine to begin with....


That's why I'm gonna go with you to fab my stuff :thunb:


You can make some cash off of this stuff Pete. Ever considered going big and doing it full-time-ish?

I know Armorology down in the Springs has a wait list 6 months out. He has no jigs, so you have to leave your vehicle with him for weeks while he builds you a bumper and I think the front bumper he did for the FJC was well over $2500 (I think......Joe/Jock correct me if I am wrong).

Quite a bit ridiculous. And I thought $800 + 130 for an ARB bumper was expensive.


Just saw this pic on the custom work section of their site.....what a stupid thing to put on Rock sliders
http://www.armorology.com/IM000421.JPG

[Brody]

You can make some cash off of this stuff Pete. Ever considered going big and doing it full-time-ish?

I know Armorology down in the Springs has a wait list 6 months out. He has no jigs, so you have to leave your vehicle with him for weeks while he builds you a bumper and I think the front bumper he did for the FJC was well over $2500 (I think......Joe/Jock correct me if I am wrong).

I figure two days for a bumper like that DeMello...wow! I wouldn't mind doing this full time as I like doing this kind of stuff. Problem is having enough work coming in consistently to do it full time, then having enough to justify a shop, plus about $10 worth of 'stuff'. The shop and upgraded tools can wait, but getting the work coming in is the big deal.

I know Armology's stuff. It is pretty good. I didn't realize they had such a long wait time for finished product...

[A-TRAC]

And I thought $800 + 130 for an ARB bumper was expensive.

Yup, Armorology isn't cheap. They make some decent stuff though. And, some people want to drop that kinda cash just so they have a "one of a kind" bumper. http://armorology.com/index.htm

[Brody]

Quite a bit ridiculous. And I thought $800 + 130 for an ARB bumper was expensive.

Price some sliders for an FJ 80 sometime if you really want to get a shocker! Ditto with any of the other FJ80 and FJ Cruiser stuff. Some of the front and rear bumpers go up to over $2600!

[A-TRAC]

I know Armology's stuff. It is pretty good. I didn't realize they had such a long wait time for finished product...

Yeah, it was like 6 months or so to get your vehicle in the shop and then 2-3 weeks to make a bumper.

Joe (Blue Thunder) should have more details. He was kinda involved in the first (and only, I think) FJC bumper armorology made.

[Brody]

Yeah, it was like 6 months or so to get your vehicle in the shop and then 2-3 weeks to make a bumper.

Joe (Blue Thunder) should have more details. He was kinda involved in the first (and only, I think) FJC bumper armorology made.

Well, I am not super fast and I don't have all of the cool tools that can speed up my work and kinda take it to the next level, but, like I said, a start to finish bumper like that DeMello, sans template or jig, would be a two (long) day project for me. Wouldn't cost anyone any $2500 bones, either....Sean and I could probably bust something like this out in one long day.

[Mporter]

Armorology makes some nice looking stuff....but damn, for that price ill get ALL my armor, and a winch done.....

[Brody]

Armorology makes some nice looking stuff....but damn, for that price ill get ALL my armor, and a winch done.....

For that price I would almost do all of your armor and buy the damn winch..plus do the install...

[RockyMtnHigh]

(I think......Joe/Jock correct me if I am wrong).

We've never really got a straight answer from Chuck on that, the price hovers between $2500 and at times has been $3000+, I think he is embarrassed to actually say what he paid for it and forgets what he told us the last time. :lol:

[Roo]

Nice work Pete! Wish I had the extra coin to take that off your hands. I have a feeling this is gonna end up Pathrat's to go with her new rear bumper. If not you shouldn't have any trouble selling it.

[A-TRAC]

Nice work Pete! Wish I had the extra coin to take that off your hands. I have a feeling this is gonna end up Pathrat's to go with her new rear bumper. If not you shouldn't have any trouble selling it.

Haha. I thought about PM'ing you and Pathrat to see if you guys wanted to get the bumper cheap and have Pete fix it, but was on the road and didn't want to deal with it. Travel has been crazy lately.

If it ends up on Pathrat's FJC, good for her.

Props to Pete for jumping in and getting it done.

[Roo]

Haha. I thought about PM'ing you and Pathrat to see if you guys wanted to get the bumper cheap and have Pete fix it, but was on the road and didn't want to deal with it. Travel has been crazy lately.

If it ends up on Pathrat's FJC, good for her.

Props to Pete for jumping in and getting it done.

Oh, I saw it as soon as you posted it up for sale. I think Pete did the right thing by going ahead and getting it and fixing it. I hate to say it but I was skeptical that it would never be the same again. Pete proved me wrong on that and even made it better:thunb:.

Hmmm, I know some people want to help me get it by sending me a ton of windshield repair and headlight restoration business:):D:lol:

[KnuckleHead]

Looks really great Pete... you do some really nice work... I like the fact that you went and made it stronger for the next person...

[Brody]

Looks really great Pete... you do some really nice work... I like the fact that you went and made it stronger for the next person...

Thanks Happy! I was looking at it and went "If this was mine...." then I added the additional pieces. Not much, but it is considerably stronger...

[Mporter]

Oh, I saw it as soon as you posted it up for sale. I think Pete did the right thing by going ahead and getting it and fixing it. I hate to say it but I was skeptical that it would never be the same again. Pete proved me wrong on that and even made it better:thunb:.

Hmmm, I know some people want to help me get it by sending me a ton of windshield repair and headlight restoration business:):D:lol:

I do have a little crack/chip in the middle of my DS shield.....I may be contacting you sometime :cool:

[Brody]

I do have a little crack/chip in the middle of my DS shield.....I may be contacting you sometime :cool:

Do this! Reese is really, really good. He has fixed stuff on Chris' rig and our Escort.

[JeffX]

Armorology would be closer to $1500. For that price you're gonna get something much stronger than an 80# bumper.

http://farm2.static.flickr.com/1372/653019492_a56847a9f5.jpg

[Pathrat]

I just was forwarded this thread. I have not been on much this week and apparently have missed a few relevant posts.

I heard this might end up on my rig and the deliberations will continue until this evening, when I understand there is a kind of deadline. Brody, you'll hear from us.

And does anyone know how this bumper impacts the airbag???

[A-TRAC]

And does anyone know how this bumper impacts the airbag???

None of the after-markets bumpers change the way airbags work on the FJC. The airbag sensors are not in the bumper, but somewhere under the lights or something.

I can research and tell you the exact location of the airbag sensors if needed.

[Brody]

Here Stephanie:

"No modifications to any factory components need or should be made to install your Body Armor FJ Bumper. Air-bag sensors and A/C line are not affected, and if so equipped, the OE chassis skid plate bolts into the factory location."

And another:

"The sensor/s are not mounted in the bumper usually. At least in the cars I've worked on. The sensor does not work by contact. The jolt from impact is what sets one off."

And yet one more:

"the airbag sensors (decelerometers) are on the front crossmember of the frame and not the bumper. The technology makes the bumper issue irrelevant from my understanding."



The same applies to the DeMello bumper.

[1freaky1]

Pete that did turn out purdy nice, it will definitely will hold up more than it did originally.

If anyone else wants some bumpers, sliders or anything fabbed definitely hit Pete & me up, we usually get the bumpers done with in 1 or 2 days depending on what all is wanted on them. So far our prices have beaten most of the ones you purchase from the big companies and some of the other shops around town. We are going to putting a page together of the stuff we have fabricated to give you all a general idea of our work, here soon.

[Mporter]

Great idea Sean. Hopefully I'll be getting with pete soon enough to start getting plans for my sliders runnin.

[1freaky1]

Great idea Sean. Hopefully I'll be getting with pete soon enough to start getting plans for my sliders runnin.

That is good news Matt just let us know when you are ready.

[Brody]

Probably so , but at what cost in weight? No problem making any bumpers out of 1/4" or 5/16" steel, but you sure pack on the pounds pretty quickly. A mix of 1/8" and 1/4" seems to be a happy medium, provided that critical gussets or braces are installed in the right places. I added some to the DeMello bumper where they would do the most good at a very small penalty in weight.

This is actually one of the things I have seen on many mass produced bumpers, simply because it is the quickest way to mass produce them. Yeah, they do have some bracing as a matter of course, but more are usually needed. This is one of the benefits of doing 'one off' custom bumpers: the attention to details like that. And they don't have to cost a fortune, either...


Armorology would be closer to $1500. For that price you're gonna get something much stronger than an 80# bumper.

http://farm2.static.flickr.com/1372/653019492_a56847a9f5.jpg

[RockyMtnHigh]

I can research and tell you the exact location of the airbag sensors if needed.

There's a bar that runs across the front of the radiator, that the sensors sit on, 2 one on each side.

[Roo]

"the airbag sensors (decelerometers) are on the front crossmember of the frame and not the bumper. The technology makes the bumper issue irrelevant from my understanding."



I have heard this too, that it is not the impact that causes deployment but the rapid deceleration of the collision.


I do have a little crack/chip in the middle of my DS shield.....I may be contacting you sometime :cool:

My number is on the website link in my sig. Feel free to contact me anytime. The sooner you have it fixed the better it will look(there is less dirt and contamination in the break.) The best thing to do is cover it up with some clear packing tape or scotch tape to keep it clean(not duct tape, too much adhesive). My website also has a plethora of info about windshield repair. Take care!

[Pathrat]

Thanks Brody and A-trac for the sensor information!!!

[JeffX]

Probably so , but at what cost in weight? No problem making any bumpers out of 1/4" or 5/16" steel, but you sure pack on the pounds pretty quickly. A mix of 1/8" and 1/4" seems to be a happy medium, provided that critical gussets or braces are installed in the right places. I added some to the DeMello bumper where they would do the most good at a very small penalty in weight.

This is actually one of the things I have seen on many mass produced bumpers, simply because it is the quickest way to mass produce them. Yeah, they do have some bracing as a matter of course, but more are usually needed. This is one of the benefits of doing 'one off' custom bumpers: the attention to details like that. And they don't have to cost a fortune, either...

Actually, that bumper wasn't to heavy, just because it has a slim profile.

It looks like you did a great job on that FJ bumper (stronger than before). Didja find a buyer?

[A-TRAC]

I think that the bumper actually weighed less than a comparable ARB..

Yeah, the ARB is one of the heavier bumpers for the FJC. 150lbs vs 84lbs for the Demello.


Sean and I are going to try to prototype both a tube and a plate style bumper with a winch mount for the FJ that we can sell for under $700

Here's a link to a thread with almost all of the mass produced bumpers for the FJC in one place. http://www.fjccentral.com/showthread.php?t=7734

[A-TRAC]

Speaking of ARB Bumpers, Toyota of Dallas is running a special on them this month.

$889 for front FJC ARB Bumper + IPF Lights...

http://www.fjcruiserforums.com/forums/fjcruiseroffroad-com/96537-arb-bumper-sale-plus-free-lights.html

Price for bumper on ARB's site is $1,154.14 and lights is $156.68, so $889 for both is definitely a killer deal.

[JeffX]

Yeah, the ARB is one of the heavier bumpers for the FJC. 150lbs vs 84lbs for the Demello.



Here's a link to a thread with almost all of the mass produced bumpers for the FJC in one place. http://www.fjccentral.com/showthread.php?t=7734

W-O-W-!

You deleted the correct information, but left this?

Just to reiterate, The (FJC) ARB weighs ~120#.