6th Gen Hilux High Clearance Front Bumper Kit

From: USD$667.25

This is a high clearance DIY weld-together winch bumper kit for the 6th Generation 1997-2004 Toyota Hilux. It features a bolt-on design, protected winch mount, and one of the best approach angles of any bumper on the market. This bumper allows you to forget about approach angle and substantially improves the offroad capability of your 6th gen Toyota Hilux! It offers excellent protection from rocks, trees and animal strikes and has been kept to a weight of 72lbs through careful design work. And unlike many other bumpers on the market, absolutely no modification of the vehicle frame is required and the vehicle can be easily returned back to stock if desired.

The main section of this bumper is CNC-bent out of a single piece of  3/16" (5mm) P&O Steel. This greatly reduces the amount of welding and grinding required by you and makes for a cleaner finished product. If you are paying to have the bumper assembled by a welding shop, this significantly lowers the cost.

SKU CO107333 Category


The profile of this bumper has been designed with maximum ground clearance and approach angles put first. The bumper sits as high and tight to the front of the 6th Generation 1997-2004 Toyota Hilux, while the angled lower faces will smoothly slide over obstacles and ensure you do not get hung up on the trail. The side wings of this bumper wrap around to the front wheel wells and tie directly into the main frame mounting plates for true offroad protection. These side wings will take a serious hit without flexing or deflecting into the vehicle body. We know that most Toyota Hilux owners want to run oversized tires and more aggressive wheel offsets. This can create interference issues with the stock front bumper. We have thought ahead and specifically designed these bumper side wings to easily clear 37″ tires. This bumper uses a total of 10 factory mounting points to solidly mount it to the frame. While this is certainly overkill, this distributes impact and winching forces evenly across your frame and makes for one of the strongest mounting interfaces of any bumper on the market.

We finished this bumper off with integrated light buckets for surface mount LED pod lights (custom light cut outs available by request), an integrated winch mount to accept all standard 8-12k lb winches with removable solenoids, and heavy duty 9/16″ (15mm) thick recovery points that are placed directly in line with the 6th gen Toyota Hilux frame to eliminate any leveraging effects. These recovery points are formed by laser cut steel plates that pass through the bumper shell and bolt directly to the Toyota Hilux frame as part of the bumper’s main mounting brackets. The recovery points then get welded to the in and outside of the bumper shell. These factors all combine to form recovery points that minimize stress on your Toyota Hilux frame and are essentially indestructible! What could make this bumper even better? The low profile design has resulted in very reasonable weights of 81.6 lbs (37.1 kg) for the steel bumper and 40.3 lbs (18.3 kg) for the aluminum version. Considering that this bumper replaces your factory bumper and associated components (23.1lbs (10.5kg)), the resulting weight increase to your Toyota Hilux is negligible at best. This minimizes added stress on your vehicle, maintains precious payload capacity, and allows you to keep your factory suspension if desired.

•DIY Weld-together kit – This bumper arrives as precision CNC-laser cut and bent pieces that you then weld together (detailed assembly instructions included)

•CNC-bent plates greatly reduces amount of welding and grinding required by you and makes for a cleaner finished product

•NO drilling, cutting or welding of the vehicle required – this bumper can be installed and removed from your 6th Generation 1997-2004 Toyota Hilux without a trace that it was ever there!

•Low profile design is engineered to provide maximum ground clearance and complement the factory body lines – bumper protrudes less than 4″ (100mm) from the vehicle body in the center.

•Fits 4 door and extended cab Models

•Heavy duty 3/16″ (5mm) plate steel construction for maximum offroad strength and durability

•Optional 1/4″ 5052 aluminum for a lightweight yet very durable overlanding setup (41.3lb weight savings)

•Bolts directly to frame using a total of 10 factory mounting points

•Protected winch mount fits all standard 8000-12,000lb winches with removable solenoids

•Reinforced 9/16″ (15mm) thick clevis mounts allow the use of 3/4″ D-Rings and pull directly off of the frame for confident recoveries of heavily loaded vehicles

•Four integrated LED pod mounts – included slotted mounting tabs give tons of adjustment to fit a variety of lights

•Integrated license plate mount

•Optional heavy duty grill and headlight tubing hoops for added protection

•Center-only bumper section is available by special request for those who would like to build their own hybrid tube bumper, please send us an email for more info!

Additional information


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Body Lift Adjustment (NOT suspension lift)

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Cree LED Lights

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Model Year


3/4" Recovery Shackle (Pair)


Bumper assembly

As for welding, with everything designed using CAD software and then CNC laser-cut to size, the pieces fit together perfectly and this makes for a very simple assembly process. All kits come with detailed instructions with plenty of clearly labelled diagrams that are made using cutting-edge CAD software. This bumper kit is well within the ability of a novice welder and many customers have purchased it as their very first welding project with great results! This is made possible by the clean parts fit-ups and thick material. These are two factors that make welding significantly easier. Welding is one of those skills that is easier to learn than you may think and once you can do it, you’ll wonder how you ever got by without it. Alternatively, many individuals buy the kits and then have a local welder assemble it for them. Even in this case, it typically ends up being less expensive than buying a pre-fabricated bumper – especially after considering the lower shipping costs of our kits vs. fully assembled bumpers.

Bumper weight

Steel base bumper weight: 81.6 lbs (37.1 kg)
Aluminum base bumper weight: 40.3 lbs (18.3 kg)


Factory Bumper weight removed: 23.1lbs (10.5kg)


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Wondering what is involved in assembling and welding this bumper kit?

Watch the video below to see 4th Gen 4Runner Owner Garrett Logan run through the process and gives his thoughts along the way.
(The 4th gen 4runner is shown, but the build process is nearly identical to this bumper).

Wondering what is involved in assembling and welding this bumper kit?

Watch the video below to see 4th Gen 4Runner Owner Garrett Logan run through the process and gives his thoughts along the way.

Don't see exactly what you're after?

We at Coastal Offroad are more than happy to work with our customers to design their dream bumper. Feel free to send us an email (support@coastaloffroad.com) for any custom requests.