I live in a suburban area that is notorious for lots of deer this time of year.
Driving home one night I saw a deer run out it to the road.

I stopped quick and leaned on the horn for a good minute to scare the deer away, because I have seen too many stupid people just stop and watch the deer walk in front of their car and they never use the horn. I want the deer to be afraid of cars so they run away, not just waltz into the road thinking cars are safe. So... after the deer was gone, I started forward again only to have another deer run RIGHT IN FRONT OF THE CAR...
:shock:

Now... I told you that story, so I could tell you this story...

Months ago after viewing some crash photos of other xB(s), I did some tinkering and took the front end of my xB apart. I noticed how ineffective the OEM bumper is. Being an engineer (and a mad tinkerer) I reinforced it with hardened steel rod and padded it with high-density foam. I have done similar work on two other vehicles I have owned and have unfortunately "field tested" these new bumpers over the years with some minor parking lot accidents... but have proven the effectiveness. So... I knew that this would help...

http://www.scionlife.com/gallery/data/500/3955rallyxb_fb0.jpg
OEM bumper

http://www.scionlife.com/gallery/data/500/3955rallyxb_fb1.jpg
1 ½" Reinforcing Rod

http://www.scionlife.com/gallery/data/500/3955rallyxb_fb3.jpg
Waterproof foam Padding

And now back to the story...
:wink:
So... I'm going about 10 MPH and run right into the dear. WACK!!! I hear a "POP" that sounds like a big plastic box being dropped on the floor. The deer gets knocked off it's feet and rolls about 3 times before bouncing over the curb and laying in a heap on the sidewalk.
I'm thinking... "OMG my new car! Oh sh!t I broke it's legs!"
I immediately pull off the road and get out to check on the hapless critter.
The deer struggles to its feet like a drunken sailor on shore leave, shakes itself like a wet dog, then runs off into the field to join it's friends.
I am standing there amazed that the deer was unhurt, then I remember all the work I did to my car's bumper.
I hesitantly walk to the front of the car to view the damage... aside from a big greasy smear on the license plate cover and a few bits of fur caught on the edges... the car is UNDAMAGED! Woo Hoo!!!

Like my Grandpa used to say... "I've yet to find a machine that you can't make a little better."
I guess all that padding absorbed the impact and kept deer and car from getting damaged.

Score 1 for re-engineering!
:D

Dude, That is by far the coolest story/idea/field testing I have heard! Way to go man! Keep up the good work. I might have to try doing that to my car too, people drive too crazy here in California, hitting Orang Cones on the freeways and what not! (Sorry Nilo, had to do it, you are such an LA driver!) Hahaha, j/k! We may not have deer, but we have "wild orange cones" roaming around, just waiting to smash into your bodykit.


Victor

It sounds like a draw to me...so score one for the deer too. :mrgreen:

Seriously tho' good looking out.

A week after I got my new xB I went to my 30th high school reunion. On the way back a deer jumped out in front of my car. :shock:

Thanks to the anti-lock brakes I stopped short of hitting the deer and did not lose control of the car. The deer just contiued on its way.

Also I'm glad I didn't drink much at the party.

With an xB window you might end up with a deer in your lap if you were going at a decent clip.

Nice bumper improvement. I might do that down the road.

Just remember where there is one deer there is another. If one crosses the road in front of you, stop because there will be another or two right after it. I know from experience in the past.

Later

Just remember where there is one deer there is another. If one crosses the road in front of you, stop because there will be another or two right after it. I know from experience in the past.

Later

I was stopped and used the horn for almost a minute.
That's why I was so surprised that another deer came out and crossed.
:shock:

Crazy critters!

i will post the sadness soon after i take some pics.

but there WAS a semi forest preserve by my house. now in less than one week its a field for either houses or business..hmm giving me ideas.. :!: :idea: :idea:
but now no more deers since that was its habitat.

i almost got ran over and did a deer stance. the stupid jeep was coming straight at me and i was like :shock: for 15 seconds. after the jeep stopped in front of me about 1.5 foot away and i reacted i continue on my way of crossing the street.
btw it was the jeeps' fault. i look both ways first.

Have you removed your bumper cover to check to see what happened before the plastic popped back into place?

Is the wateproof padding FunNoodles? That had to set you back a dollar or two there.

i almost got ran over and did a deer stance.
like this?
http://www.dvdarkivet.no/images/largeshots/1017258703.2.jpg

LOL..OMG. that is so funny ^^^^^^^^

kinda like that

I had my box 6 days and a deer ran out of the woods being chased by a bear and BAM broadsided my car and mashed the driver and passenger door. over 1,000.00 worth of damage. The damned thing bounced off the car and took off. The next day the same deer jumped in front of me in the same area. I knew it was the same one as it was limping on the right side. That sucked.

i almost got ran over and did a deer stance.
like this?
http://www.dvdarkivet.no/images/largeshots/1017258703.2.jpg

:lol: :lol:

around here aligators and crocodiles are a big problem they go out into the road and sometimes they become roadkill

I had my box 6 days and a deer ran out of the woods being chased by a bear and BAM broadsided my car and mashed the driver and passenger door. over 1,000.00 worth of damage. The damned thing bounced off the car and took off. The next day the same deer jumped in front of me in the same area. I knew it was the same one as it was limping on the right side. That sucked.

what happened to bear?

I had my box 6 days and a deer ran out of the woods being chased by a bear and BAM broadsided my car and mashed the driver and passenger door. over 1,000.00 worth of damage. The damned thing bounced off the car and took off. The next day the same deer jumped in front of me in the same area. I knew it was the same one as it was limping on the right side. That sucked.

what happened to bear?
If it was me....
click, slam, boom, boom....shuffle, shuffle......grunt, plop....vroom, screech.


That would have been me shooting the bear (click, slam, boom, boom..)
then me dragging the bear to the back of the car (..shuffle, shuffle..)
lugging the bear into the back (....grunt, plop...)
and getting the F out of there (...vroom, screech.)
:D

Deer are dumb. I cross paths with them usually once a week. Ever wonder why they get hit. They don't run when they see the headlights (Deer in the headlights look) . And honking at them doesn't do anything either. it's good there wasn't any damage.

... Being an engineer (and a mad tinkerer) I reinforced it with hardened steel rod and padded it with high-density foam...
I've had similar ideas about reinforcing the OEM bumper... in particular, I've thought about the foam.

Could you please post a materials list and How-To (you could propably skip the removal and reassembly of the front end).

Where did you get these items?
* 1.5 " hardened steel rod
* waterproof high-density foam

Thanks for sharing your idea, pics and post. :D RPM

Have you removed your bumper cover to check to see what happened before the plastic popped back into place?

Yes I checked. No damage.
:D

Is the wateproof padding FunNoodles? That had to set you back a dollar or two there.

Give that man a prize!
It's the same high density, high impact resistant, closed cell,
waterproof foam that you can buy on-line for a LOT more money.
:wink:

I had my box 6 days and a deer ran out of the woods being chased by a bear and BAM broadsided my car and mashed the driver and passenger door. over 1,000.00 worth of damage. The damned thing bounced off the car and took off. The next day the same deer jumped in front of me in the same area. I knew it was the same one as it was limping on the right side. That sucked.

My buddy had the same thing happen with his brand new Ford Explorer.
A deer ran right into the door and caved it in.... then got up and ran away.
:shock:
Crazy Critters!

I had my box 6 days and a deer ran out of the woods being chased by a bear and BAM broadsided my car and mashed the driver and passenger door. over 1,000.00 worth of damage. The damned thing bounced off the car and took off. The next day the same deer jumped in front of me in the same area. I knew it was the same one as it was limping on the right side. That sucked.

My buddy had the same thing happen with his brand new Ford Explorer.
A deer ran right into the door and caved it in.... then got up and ran away.
:shock:
Crazy Critters!

LOL... No need for me to wait quietly in the woods all camoflauged up. I hunt deer in my moving chair. :lol:

... Being an engineer (and a mad tinkerer) I reinforced it with hardened steel rod and padded it with high-density foam...
I've had similar ideas about reinforcing the OEM bumper... in particular, I've thought about the foam.

Could you please post a materials list and How-To (you could probably skip the removal and reassembly of the front end).

Where did you get these items?
* 1.5 " hardened steel rod
* waterproof high-density foam

Thanks for sharing your idea, pics and post. :D RPM


HOW-TO BUILD A BETTER BUMPER

The metal rod was purchased from a local steel distributor (see your yellow pages).
It is a cold rolled, carbon steel, but I forget the actual hardness rating.
I think it was: 1120 Steel, 160 BHN*, with an 85% machine-ability
(BHN) Brinell Hardness Number

Remember, you have to be able to bend the rod to follow the curve of the bumper.
You can use a hydraulic press (or like me) 2 really strong guys and a LOT of leverage.

When you cut the rod make sure it extends 7” past each end of the bumper.

I think the actual diameter was 1 ¼” or 1.5" but you need to remove the front bumper and measure the inside channel to find an average. You also have to use various pry bars to reform and round the inside ends of the sheet metal bumper to accommodate the rod.

The ends of the rod must be tapered with a grinder so they don’t bind.
Use a heavy axel grease and lube up the inside channel of the bumper and about 1’ of the end of the metal rod.
Put the bumper in a heavy-duty bench vice. Have 1 really strong guy hold the bumper.
Have the other really strong guy use a very large dead blow hammer and slowly pound the curved metal bar into the channel on the bumper.
Use a large heavy-duty C-clamp to keep the rod in the channel when pounding.
Use a pipe wrench to rotate the rod if it starts to turn.
http://www.scionlife.com/gallery/data/500/3955rallyxb_fb0mod.jpg

When finished. Degrease everything with lacquer thinner and paint the entire bumper and rod.

It a very time consuming and messy process, but it doesn’t require welding and it strengthens the entire bumper, retains the OEM appearance, and provides about 7” extended ends to protect the wheels.

The foam padding is indeed a cut-up Fun-noodle pool-toy held on with GE silicone sealer/adhesive and black duct tape.
http://www.scionlife.com/gallery/data/500/3955rallyxb_fb2.jpg

The whole process is a lot of trial an error and once the reinforced bumper is back in place you will have to re-bend the ends and re-cut the foam to get it to fit properly under the plastic bumper cover.

It’s a lot of work, but it’s worth it.
:D

Holy crap man--glad you are ok and posting, haha.

Cheers,

great idea and good work.

Looks like we share interests in not only modifying cars, but also racing. Looking forward to hearing how/what you plan on doing to the xB.

For me, I'm torn by the fact that I bought this Special Edition car that should be kept as stock as possible, but also want to modify the crap out of it for handling. Specifically add on fender flares and try and sqeeze on 255 or 275 wide Hoosier tires. THAT would be one bad ___ autox car.

:evil: I was on my way to work the other night when I hit a deer. He jumped over the concrete barrier right infront of me. My little Nissan hit him in the shoulder with the headlight assembly, his head took out the rest of the grille. Now my car that I just bought and didn't even get in my name yet is really messed up. The transmission is howling bad, and it is a new one, just installed before I bought the car. oh well, looks that I'm going to have to wait even longer for my xB.


Wild Bill 8)

HOW-TO BUILD A BETTER BUMPER ...
Excellent How-To with added pics! Thanks very much. ScionLife Forum is the greatest! :D RPM

Can someone give an estimate on how much it would cost to do this?

Can someone give an estimate on how much it would cost to do this?

:idea:
Charges on MasterCard:
Hardened steel rod $25
Can of spray paint $5
2 foam funnoodles $6
Tube of GE silicone sealer /adhesive $5
Roll of black duct tape $4
Peace of mind knowing that your car's newly reinforced bumper
is stronger, safer, and can survive an impact with a deer's big fat ___...
Priceless.
:wink:

Can someone give an estimate on how much it would cost to do this?

:idea:
Charges on MasterCard:
Hardened steel rod $25
Can of spray paint $5
2 foam funnoodles $6
Tube of GE silicone sealer /adhesive $5
Roll of black duct tape $4
Peace of mind knowing that your car's newly reinforced bumper
is stronger, safer, and can survive an impact with a deer's big fat ___...
Priceless.
:wink:
Could you scan a copy of this MasterCard statement (complete w/CC#) and email it to me. I'm not entirely convinced and would like more proof. Make sure the CC account number is clearly visible. :wink:
Thank you :lol:

ohh you know you can trust him, his name is the saint :lol:

I was asked a few more queston in a PM, so I though I'd post the answers...

QUESTIONS:
What are the benefits of reinforcing the front bumper and adding foam?
Also how much weight did it add to the car?
Was it expensive to do and or involve welding?


ANSWER:
Adding a reinforcing rod increases overall strength of bumper and adds side protection near the front wheels. If you examine some of the crash photos of other xBs you will notice that if it gets hit on the front corner the damage is extensive as there is no bumper underneath the plastic to absorb the impact. It’s the most vulnerable spot in the front of the car. The weight of the metal rod I used was 7.5 lbs.

Carmakers typically “go cheap” on bumpers for reasons such as:
1. Weight
2. Cost
3. Ability to sell replacement parts (or new cars) .

No welding was involved. It took a weekend of planning and design, then a lot of muscle to pound the rod into the channel of the OEM bumper.

The foam is used to help absorb impact and also to prevent damage in minor (slow speed) accidents.
Think of it this way... imagine hitting your hand with a hammer.
:shock:
Now place a piece of high-density foam on your hand and hit that with the hammer. Much of the impact is absorbed by the foam and not your hand. The same thing happens with the bumper. In a low speed impact (such as a parking lot accident) the foam will absorb the impact instead cracking the plastic bumper cover and denting the metal underneath.

I got the idea from Saturn car bumpers which are made with massive amounts of (bike helmet) foam over their metal bumpers, then coated in plastic. That’s why Saturn’s get 5 stars in a crash and the driver can walk away from the accident. The bumper absorbs almost all of the damage.

And no, it wasn’t expensive. The foam is a fun-noodle pool toy cut up and the metal rod was scrap at a metal yard.

8)

- Rally xB

you should make a new post for just the how to! Great write up!

rallyxb

Thank you for sharing a useful good idea :D

ur a handy guy to have around

Is the wateproof padding FunNoodles? That had to set you back a dollar or two there.

I'm sorry, but that's funny :lol: :lol: :lol:

I am new here and I hope you dont mind my butting in. Unfortunalty mosification to OEM safety devices on any automobile is illegal. Of course most states also have laws making any modification to a stock suspension illegal to. I am not saying you shouldnt modify, destroy, race, mod out, or cruise your ride cause thats pretty much why we own cars but if you are ever in a bigger accident than a fender bender which will require the insurance company to dissassemble or inspect for quoteing purposes you may find yourself in some trouble. Several years ago some shmuck thought it would be cool to use a rail road tie for a front bumper and his truck. One day a nice lady in a minivan RAN a red light and he plowed her right in the passenger door killing two of 4 kids in the car. She ran the light so she got the ticket but because he midified his front bumper she (with the help of some lawyer I am sure) sued this guy and ended up with well over a million because the jury felt that his modification to his truck made the crash worse since the "crumple zone" and "impact barrier" was no longer exisiting. Instead he had a railroad tie.

good point but I don't think a fun noodle is going to mess up the crumple zone

no but the steel rod could...

and yes, in NJ it is illegal to have non-factory bumpers.

jeeps and trucks like to use 2 x 6's.
and then they wrap it with some rope...

might look trick (to some) but it is illegal.

this is more of a hidden mod, not so easy to notice if it were in an accident...

so you can't have a body kit???

that blows!

"Ichoptop" mentioned that modifying OEM safety devices on any automobile is illegal. That's a good point.:idea:

Here's another thing to think about: does this modification effect the operation of the air bags (specifically the air bag sensors)? Will a stiffer bumper make the air bags more likely to inflate in a low speed accident? Will it make them less likely to inflate in a higher speed accident? :?:

I don't have the answer to this one, but I do know that is not unusual for sensors to be tuned to the specific design of the vehicle. Are there any "air bag" experts out there? :?:

:evil: I was on my way to work the other night when I hit a deer. He jumped over the concrete barrier right infront of me. My little Nissan hit him in the shoulder with the headlight assembly, his head took out the rest of the grille. Now my car that I just bought and didn't even get in my name yet is really messed up. The transmission is howling bad, and it is a new one, just installed before I bought the car. oh well, looks that I'm going to have to wait even longer for my xB.


Wild Bill 8)
How about taking the insurance money, junking the Nissan and using the money for a down payment on an xB. :wink:
I'm not trying to downplay the pain from losing your car in an accident. Its one of Murphy's laws that once you make a major repair to a car it gets in an accident. :?

I am new here and I hope you dont mind my butting in. Unfortunalty mosification to OEM safety devices on any automobile is illegal. Of course most states also have laws making any modification to a stock suspension illegal to. I am not saying you shouldnt modify, destroy, race, mod out, or cruise your ride cause thats pretty much why we own cars but if you are ever in a bigger accident than a fender bender which will require the insurance company to dissassemble or inspect for quoteing purposes you may find yourself in some trouble. Several years ago some shmuck thought it would be cool to use a rail road tie for a front bumper and his truck. One day a nice lady in a minivan RAN a red light and he plowed her right in the passenger door killing two of 4 kids in the car. She ran the light so she got the ticket but because he midified his front bumper she (with the help of some lawyer I am sure) sued this guy and ended up with well over a million because the jury felt that his modification to his truck made the crash worse since the "crumple zone" and "impact barrier" was no longer exisiting. Instead he had a railroad tie.


I understand your concern however, please consider the following:

1. I am an engineer and a mechanic. My Brother, Father, and Grandfather are all master mechanics. From an experience standpoint, I think I’ve got it covered. From a technical stand point I have proven history of my vehicle modifications being effective and safe. The one time I had to make an insurance claim because of a hit and run in a parking lot, the insurance adjuster was very impressed with my bumper work and said without the modifications the damage would have been a lot worse. He actually encouraged me to submit my design modifications to Nissan.

2. I did not design the bumper to be indestructible. I merely reinforced the OEM bumper to more evenly distribute the force of an impact across the entire surface area as well as add protection the front wheels.

3. Crumple zones are built into the cars uni-frame and safety cage. They were not modified.

4. The air-bag sensor is located on the driver’s side, bolted to the vehicles uni-frame, behind the bumper. It is activated by the g-forces encountered during an impact. It is NOT attached to the bumper and will activate in a crash if the bumper is there or not.

5. The steel rod I used was bent by hand (using lots of muscle and leverage) I think a vehicle impact will be able to bend it.

6. Pickup Trucks and SUV are major accident problems in general. Their bumpers are a non-standard height and frequently override a cars bumper in a crash, thus bypassing all the impact absorption capabilities of the cars bumper. Furthermore they are exempt from many of the safety laws and standards for cars.

7. My sympathies to the lady who RAN the red light, but any impact into the side of a vehicle, where there is no bumper and very little crumple zone can prove to be fatal.

8. I am not aware of any laws in NYS regarding the modifications of bumpers. More research is required.

Peace.
8)

- Rally xB

it's all good rally,

just really saying that if a lawer wants to press the issue they can...

my personal feelings are, i like it...

Ralley, I'm not baggin on you at all. Unfortunatly thats what the DOT and state law (at least in colorado) state therefore all my cars for the last 18 years have been illegal in some way or another. I am also a mechanical engineer for the last 10 years, I have worked for automotive aftermarket companies, the DOT, and SEMA during my career. I, like you, know what I am doing when swinging wrenches around but all of this wont mean squat when after a wreck a lawyer overhears the insurance adjuster talk about a modified front bumper that was involved with a wrech and takes a case before a bleeding heart jury.

Ralley, I'm not baggin on you at all. Unfortunatly thats what the DOT and state law (at least in colorado) state therefore all my cars for the last 18 years have been illegal in some way or another. I am also a mechanical engineer for the last 10 years, I have worked for automotive aftermarket companies, the DOT, and SEMA during my career. I, like you, know what I am doing when swinging wrenches around but all of this wont mean squat when after a wreck a lawyer overhears the insurance adjuster talk about a modified front bumper that was involved with a wrech and takes a case before a bleeding heart jury.

I totally understand an appreciate the warning. Lawyers are troublemakers anyways. However, I'd rather improve my chances of surviving a wreck than worry about some law suit that may never happen.
:wink:

Lawyers are troublemakers anyways. However, I'd rather improve my chances of surviving a wreck than worry about some law suit that may never happen.
:wink:

I totally agree! I think I've said it before, but I'll say it again, great work!