Guide: Rear bumper cover “clearance chop”

Guide: Rear bumper cover “clearance chop”
2016 ORP

>This cut likely precedes dom tubing weld work
>To get out ahead of that did the bumper cover cut myself, so I’m to blame if it’s janky
>Note:
rear bumper cover was already was painted black on lower portion in a separate project.
factory rear mudguards previously cut off with a reciprocating saw.


1. YouTube how to remove bumper cover and do that. Unclip the valance easily from backside.


Mask off and then spray out flat black the lower half of the newly exposed painted metal that lies behind the rear wheels, and under hatch a bit.


Spray inner foam piece flat black. Add a couple 3M Velcro strips between foam and crossmember.


*I bent undercarriage fastening brackets UP with a rubber mallet, since they ain’t doing anything no more.



2. Tape off a straight line on bumper cover using masking tape, starting just under the third fastener from the seam with the body (12” down from seam), and line that mark up with the top edge of all the valance clip fastener slots in bumper cover. (If you don’t have valance trim, the cut is 1-3/4“ down from top surface of bumper cover step).





For the fender liner behind wheel, cut it in a straight line across starting from your cut line that’s just under third fastener from seam (12” down from seam)




3. Trace top edge of the masking tape with a dry erase marker. Remove tape and fix your cut line where needed. I tried to stay parallel with the horizontal bumper/body seam.


4. Fasten bumper cover upside down, to some kind of table or platform, using screws through inconspicuous existing holes.



5. Wear eye & ear protection. Cut your line with a corded Dremel tool, recommend cutoff wheel No. 409. I broke like 4 of ‘em. Let the melted plastic pelt your face!





6. Peel what you can off cut edge by hand. Sand edge quickly w/ 120grit, I used a corded multitool.



7. Reinstall bumper cover.



8. Install black automotive edge trim w/ heat gun, especially if you’re below 18°C/65°F. I bought at Canadian Tire.





Sink a self tapping screw through fender liner into a metal bracket area behind it, between the second and third fastener down from seam.



Extra angles:

 

Just completed a couple flat black touch ups underneath, 3 months later.

 

*Removed hitch as well, but keep it with me in a Pelican case.

https://www.4runners.com/threads/how-to-remove-5th-gen-rear-hitch.42785/

 

VERY well done DJ
Simply awesome

 

Is your intention to do a rear bash bar type set up with side hoops?

 

That’s exactly right yeah, like dom tubing. same idea for the front bumper as a matter of fact.

just seen this new high clearance bumper at my local shop, very interested !

 

Brand?
Green lane? That’s up there
Kinda C4 but not as bulky

looks sick dj
No more 80%off style huh

n on the 8th day, there was contemplation

side ?: I think I already asked, but is any of the rear valance used in your cut?

Could you get away with the chop n not put it back on?

 

Coastal Offroad builds many of their own bumpers, I believe this one’s brand is Coastal Off-road.

*no I didn’t keep any of the valance because the cutline is located directly across the horizontal holes that are in the bumper cover for the valance clips

 

So 80% Offroad has some great options as well and yes, I am contemplating lol as I often do. I think in the short term first I’m going to order the 80% Offroad low profile recovery point in place of my hitch.

 

dropping this here :

 

Nice write up!

Biggest advantage of the 80% kit is the weight. It just adds the armor where you need it.

My 34" spare fits in the OEM location. When I move to 35's I'll consider building a swingout and relocating the backup camera.
If I wasn't concerned about the spare tire or weight I'd have gone with outgear solutions. IMO this is the best rear bumper setup for the 5th Gen.