2003 Toyota 4Runner Unlimited - Skill Meets Metal - Tech

This is a slick way to close off a tube. First, a diagonal slice is made, and then an oval pattern is built and subsequently created in metal. After the oval cap is welded in place, the welds are sanded smooth for a finished appearance.

Here's the main hoop with two bends completed, two to go. The distance to the bends was marked from the center outward.

A second set of supports were made for the main hoop. These began at the lower cross bar.

After the tubes were tacked into place, they were partially welded with the bumper attached to the 4Runner. For final welding, the bumper was removed and set onto the welding table, after which Greg added plate mounting tabs and sent the whole works out for powder coating.

When we returned, the former lengths of raw tubing and pieces of steel plate had become a gorgeous assemblage of powder-coated off-road art. Desolate also made a complete set of panels to cover the sides and center of the bumper. The OEM side marker lights were replaced with a pair of low-profile LED units that tuck nicely into the flat-black side cover panels.

The center skid plate received three large holes to facilitate additional airflow, and mounting holes were marked and drilled for the front license plate. The end result is shown in this story's lead photo. It's everything we needed and has the looks that we wanted. To say the least, we're stoked.