see the cost of a "steel" grill guards that use 1/16 steel pipe, the same thickness as the stock bumpers, I'm realizing that all the really heavy duty true grill guards are close to $900-1000.
Knowing that lb per lb aluminum is stronger than steel.
Well a 20 ft section of 5x3x3/16 sq steel tubing is $45. W/ 1x1x1/4 pipe at 12/ 20ft.
I could conceivably build a VERY strong bumper/grill guard at a reasonable price.

Now i can also get aluminum in 6"channel at 149/ 20ft.
I thought i've seen aluminum welding rods before. Since i have an arc, I'm going to make my own. I think that the aluminum would be so trick, but how hard would that be to weld.

Anyone have any trick custom bumpers. I know how to follow the original contours. It'll have four cuts on each side which will allow the new bumper to have almost the same basic contour as the stocker.
I hope to have it done by next weekend.