6th Gen Hilux High Clearance Rear Bumper Kit

From: CAD$837.00

This is a high clearance DIY weld-together bumper kit for the 6th Generation 1997-2004 Toyota Hilux. It provides full wrap-around protection for the rear of your 6th Gen Hilux while the sloped, high clearance design hugs the rear of the vehicle for unbeatable ground clearance and departure angle. Simply put, you can not get any more rear end clearance than this without cutting into the body of your Hilux! This bumper is a direct replacement for the factory rear bumper but also wraps around the sides of the body for total quarter panel protection. The rear quarter panels are often the most vulnerable piece of body work on a 4x4. Keep them protected!

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Description

When we set out to design this bumper, we wanted to create something that packed as much functionality as possible while still looking great and complementing the lines of the iconic 6th Generation 1997-2004 Toyota Hilux. The low profile wrap-around design and optional side hoops will take your 6th gen Hilux’s offroad performance to new levels. The sloping rear profile and optional recessed hitch receiver further increase clearance and provide a smooth surface to slide over obstacles. These features make a very noticeable difference during deep ditch crossing and steep obstacle climbs where other aftermarket bumpers with bulky rear profiles will hang up and impede progress on the trail. Simply put, this bumper allows you to forget about departure angle and substantially improves the offroad capability of your 6th Gen Hilux!

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.

We realize that at the age they are now at, many 6th Gen Hilux’s can have frames that are rusty or otherwise damaged in some way. For this reason, we went completely overkill with the mounting system for this bumper. It includes 5 mounting points per side for a total of 10 mounting points! These mounting points use factory holes in the frame and are distributed over a massive 13″ (330mm) of length of the main frame rails. While this is overkill, it ensures the impact and pulling forces are distributed evenly over the vehicle frame. This also results in wrap-around side wings that are properly supported and worthy of real offroad abuse.

Unlike many aftermarket bumpers that are more or less empty shells with minimal reinforcement, this bumper contains extensive internal ribbing and mounts to the bottom and sides of the vehicle frame for unmatched strength and stiffness. The bumper side wings are tied directly into the vehicle frame using gusseted support brackets, meaning they can take serious offroad hits without flexing into the vehicle body. With this bumper, you’ll be able to tackle challenging trails with a new level of confidence knowing that the rear end of your 6th Gen Hilux is now nearly invincible!

The low-profile design of this bumper keeps the weight extremely reasonable at 113.9 lbs (51.8 kg) in steel and 55.7 lbs (25.3 kg) in aluminum while maintaining excellent strength. This is especially noteworthy when you consider the fact that the factory hitch receiver, frame crossmember and rear bumper all get removed before installing the Coastal Offroad bumper. This means that even with our steel bumper version, the total weight increase to your vehicle is negligible at best (Our aluminum version will actually cut weight from your Hilux!). This minimizes added stress on your vehicle, maintains precious payload capacity, and allows you to keep your factory suspension if desired.

We finished this bumper off with a recessed hitch receiver and heavy duty 9/16″ (15mm) thick recovery points that are placed directly in line with the vehicle 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 Hilux’s 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’s frame and provide reliable recoveries of heavily loaded vehicles in the worst of offroad situations. To further protect the vulnerable rear corners of your Hilux, this bumper is available with optional tubing side hoops that will help push your vehicle away from trees and rock walls.

The swing out tire carrier comes in either a single or dual sided configuration and is built to accept a tire up to 37″ in diameter! Both carriers include mounting brackets for a hilift jack and other recovery items. The dual swing out includes the hilift mount as well as a lockable jerry can holder designed to fit two 20L NATO style jerry cans. These carriers feature heavy duty chromoly heim joint hinges, 2000lb toggle latches, T-handle spring pins, and a replaceable UHMW catch pad that provides secure, rattle free operation. The heim joints in conjunction with the toggle latch provide tons of adjustability, allowing for easy assembly and guaranteed alignment of the carrier latch. The single swing out add-on weighs 34lbs and the dual swing out add-on with gas can holder weighs 77lbs.

•DIY Weld-together kit – This bumper arrives as precision CNC-laser cut 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 frame or body are required – this bumper can be installed and removed from your Toyota Hilux without a trace that it was ever there!

•Slim profile is engineered to provide maximum ground clearance and complement the factory body lines

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

•Optional 1/4″ 5052 aluminum construction for a lightweight yet very durable overlanding setup (58.2lb weight savings)

•Optional recessed 2″ hitch receiver for a clean look and further clearance gains (While the hitch is very well reinforced, we cannot rate it for on-road towing due to the DIY welding nature of this kit)

•Bolts directly to frame using 10 factory mounting points for unbeatable strength – uses all factory mounting holes

•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

•All kits ship as clean, bare metal that is ready to weld out of the box – the Nitrogen laser cutting technology means no cutting edge oxidation and thus easier and stronger welds

•Optional Single and Dual Swing out carriers with spare tire mount, hilift jack mount and locking dual NATO can holder (dual swing out only)

Additional information

Body Lift Adjustment (NOT suspension lift)

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Material

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Cree LED Lights

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Recessed 2" Receiver

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Rear Quarter Protection Hoops

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3/4" Recovery Shackle (Pair)

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Swing Out Tire Carrier

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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 (includes hitch receiver and crossmember): 113.9 lbs (51.8 kg)
Aluminum base bumper weight (includes hitch receiver and crossmember): 55.7 lbs (25.3 kg)

Factory Bumper + Hitch Receiver weight removed: 99 lbs (45kg)

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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.