Study existing 4runner rear bumpers and analyze for fit
3d scan disassembled car with portable scanner
Integrate into Rhino3D for design of new rear bumper cover
Fabricate new bumper cover out of steel after prototyping with cardboard first to ensure fit
With the strong desire to add off-road capabilities to my 2006 4Runner, I set about looking for a replacement rear bumper that could handle the rigors of trail and off-road work. While several specialized companies do already make these bumpers from steel plate stock, making my own is more fun.
With that in mind, I set out to design and build a new one from steel, utilizing a local waterjet cutter for fabrication and using a handheld 3D scanner that had been loaned to me.
After disassembling the rear bumper cover of my truck I 3D scanned all the frames and mounting points to see where I might be able to mount a new bumper. Through combining several scans from the DPI8 to create a full picture of the car's frame and body I will begin the process of designing a new bumper to allow for precise and (hopefully) easy fitment.