Hamman's 2012 OS Build Thread
 

So, I thought I'd just start a new thread regarding my 2012 OS and mods we have done! First, off we are just about finished with what I believe is the first ever custom front bumper on an Outlander Sport. It is fabricated out of 1 1/2 90 thou. tubing along with some 1" and 3/4" tubing. There is still a bit to do. I need to weld in a light bar mount, winch mount and just a few more gusset supports. Along with swapping the aluminum air dam out with a mild sheet steel that covers some of the vitals a bit more. I also need to relocate the oil cooler to behind the air dam and run some wiring! But I think it looks great and will really flow well with the car once the rest of the mods are done! Hope you dig it!

Completed Mods:
Custom tube bumper
1 1/2 wheel spacers
215/75-16 Toyo Open Country AT 2's (we plan on swapping out the wheels and tires in the near future)
Roof rack with random crap on it
Curt Hitch and wiring kit
K&N air filter
Debadged emblems
Bed liner on rims and wheel arches
Hood Pin's
Vinyl eyelids

To be done Mods:
2" spacer lift
30mm bolt on fender flares
New roof rack with rotopax/tool setup and canopy
Custom rear bumper with tire carrier
Rally armor mud flaps
More exterior lighting
Aluminum fuel door
Either plasti dip or get vinyl wrapped with company info and new color :)
24" light bar for bumper
32" light bar for roof rack

On to the pics! The bumper is still a bit rough at this point, I need to hit it again with the flap disc, clean up some welds and put on some bed liner!!! https://cimg6.ibsrv.net/gimg/www.evo...46169f7bcc.jpg
https://cimg8.ibsrv.net/gimg/www.evo...3120d02c30.jpg

https://cimg1.ibsrv.net/gimg/www.evo...481e874df4.jpg
https://cimg5.ibsrv.net/gimg/www.evo...9c0b12a2fd.jpg
https://cimg4.ibsrv.net/gimg/www.evo...41e0face0a.jpg
https://cimg7.ibsrv.net/gimg/www.evo...940ab4f2ef.jpg

This morning I had some time so decided to bang out the new radiator and condenser. Luckily, the fans and housing were ok. I had to do a little bit of plastic welding on some of the housing but nothing that effected performance or durability. Just need to get the A/C system refilled now. Took me almost an hour just cleaning all the old crusty coolant off :(https://cimg1.ibsrv.net/gimg/www.evo...87b9b87f6a.jpg
https://cimg2.ibsrv.net/gimg/www.evo...a6b69204e8.jpg

Bumper has been bed lined! I just used some bed liner in a spray can from Lowes, works great and sprays nice and clean. Ive had good success with this on my Xterra bumpers too. I need to pick up some more sheet steel this week and make a new lower air dam. The aluminum works good and looks ok but I just want more protection and I still need to relocated the oil cooler. https://cimg2.ibsrv.net/gimg/www.evo...45220973f2.jpghttps://cimg3.ibsrv.net/gimg/www.evo...c2f2ec55db.jpg

Wow! Nice work, what is up with the square under the driver side headlamp?

:headbang:

It's a vent. There was a small crack there from when we hit the deer so decided to cut it out and toss in a 6" vent/louvre thing. Serves absolutely no purpose haha ;)

Reminds me of a mod I see a lot on 350Z, maybe you can find a little vent cover that will fit yours!

https://cimg4.ibsrv.net/gimg/www.evo...1ba6308f24.jpg
https://cimg3.ibsrv.net/gimg/www.evo...5066b92351.jpg

Thanks man, that looks rad. Ive looked for those too but wanted something unique. Don't really see louvers on bumpers so though, why not!? I may do one of those on the other side as there is a big crack from the deers head smacking into it. :)

Ok so the front is almost done, just a bit more sheet work to do. I am off to the rear now :) Tube bumper tire/rotopax carrier! Ive got a bit of 1.5" tubing left over. I am going to weld/bolt it onto the rear bumper that bolts to the actual frame. I am going to go through the plastic bumper cover with some holes that will hug the tubing. I made a bumper on my Xterra that held up a 35" MT tire so this won't need as much support but still want it safe/functional. I am going to order a pivot/bearing from A to Z fabrication. They have a standard and heavy duty kit for like $50 that gets welded to the tubing and then another pivot arm gets welded to that so it swings out and away! Here is where I am thinking of location to swing away from traffic. It will swing to the right. You can't see it, but the left light is not covered. Just the part on the hatch, but I don't think that does anything except for the reverse light which the right side is still fully visible....Oh, and relocate the plate to somewhere else of course :)
https://cimg4.ibsrv.net/gimg/www.evo...0adaa0ff0f.jpg

OS tire carrier
https://cimg5.ibsrv.net/gimg/www.evo...0e1409b61e.jpg

OS tire carrier

Here is a horrrrrrible photoshop rendition of the carrier, rotopax and bolt on flares :)
https://cimg6.ibsrv.net/gimg/www.evo...bdf0a2d5a6.jpg

tire carrier mockup

^
Very cool!

How about something in line like this >
(and as a Double Bonus.. If you can make it where it mounts into your hitch socket, so the whole thing is easily removable, when not needed!! :headbang: )
http://www.4x4xplor.com/images/LoD-X...n/DSC00523.jpg

That would be nice to have it mounted to the hitch to make it less permanent I suppose :) I have been going over a few different ways of mounting, just need it to be as stout and strong as possible when holding a 235 spare tire and 2 gallons of fuel. I had a setup similar to this on my Xterra. It was all welded to the hitch which was then bolted to the frame, so in turn was removable I suppose....I'll keep it updated as I go!

https://cimg3.ibsrv.net/gimg/www.evo...14fdd370ee.jpg
So, this took me pretty much all morning :) Concept of how I want my OS to look. I am holding off on the tire carrier for a bit. I want to do the lift, flares and snorkel first and see if it is even needed. I may just end up getting a bigger basket and tossing the spare up there. If a full size spare fits in the hatch area where it already is then I may just leave it but trim up the rear bumper a bit to match the front.

And why not with some un-needed bead locks, You know, for all those insane trails and deep creeks I'll be crossing! :lol:
https://cimg1.ibsrv.net/gimg/www.evo...6134d654d2.jpg

Just did another photoshop but with light cages instead of light bars. I think the Cages look better but would cost much more to build...The light bars can be had pretty cheap and easy to mount..Also thinking about going with a nice set of black steel rims and faux bead locks. Also added a shovel & axe mount. ;)
https://cimg2.ibsrv.net/gimg/www.evo...2f1da574b6.jpg