I think you're right... I didn't really think it would decrease only by that small amount. I was expecting near 300-400lbs of additional weight being put on, and then throw in the factor of bad aero, possibly kicking it down 2-3mpg's... Yea, 5 gallons is quite a lot of fuel.You might be overthinking the weight. After removing the rear hitch and bumper, my custom bumper + swing-out only added like 35lbs. Mine is pretty minimalist, but I still wouldnt expect more than 75-100 lbs added to the rear for even a heavy-duty bumper. And, similarly, adding a 150lb bumper to the front might only add around 110-120 lbs of total weight after removing stock stuff. A winch is another 90 or so with a steel cable, or about 65 with synthetic.
All else being equal, adding 200lbs to a 4500lb vehicle will reduce mileage by a bit over 4%, (about 1 mpg) and maybe a little more on the highway with a real aggressive design that exposes the front tires. Thus, assuming you got 20mpg before (optimistic? ;) ), a 5 gallon Jerry Can still adds about 95 miles to your total range :) .
As to the safety....
My wife hit a tree in her first 5th gen 4runner and completely totaled it. The frame was only very slightly tweaked, if at all, but a lot of the body forward if the doors was pretty wrecked. I am almost positive that a solid front bumper would have minimized damage to the vehicle, by inherently negating most of the factory-designed crumple zones. Would she likely still have been fine? Almost certainly, yes. But, I think it is a little naive--and possibly irresponsible--to assert that solid steel bumpers, which will severely hamper the body's ability to crumple on impact, could possibly result in less energy transferred to the occupants on impact.
That said, I have steel bumpers on my 3rd gen 4Runner and happily drive around with my wife, dogs, and even my newborn in the car. But, I am still certainly aware that, at least to some degree, my modifications have technically made the vehicle less safe (especially in front impacts).
Just wondering, what rear bumper do you have, since it only added 35lbs? That's quite impressive.
Yea.. I had a feeling that steel bumpers would negate the safety... But... I hope I won't have to go through that again.. Glad your wife is okay!