Dented up my stock one pretty bad. Decided to whip up something beefier. Main middle c-channel is 3/16" mild steel, the end pieces were off cuts of a log truck cab guard, and are 3/16" T-1. Still need to put a top plate on to run up under the trim piece under the door. Also need to make end caps.

 

Heres the ends welded on.

 

Left side

 

Rh side. Weld not quite as good

 

All painted

 

Absolutely functional and I don't think it will break if you hit it when it's cold, looks good.

 

YES!!! Its good to see some one actually build something vise buy it. Rigs look better when its not that stupid "store bought" junk. If my son picks up the 2000 D2 he is looking at, bumpers come off and we'r building a set. Also will be building a roof rack.

 

Here is a built from scratch roof rack and scratch jerry can holders. No plans used just build as u go!

 

Exactly where I am...2000 D2...cracked that POS rear bumper skin the LAST TIME!!! I bought 25ft of 5" 6061 T6, .480" web w/ 2.5 flanges...Then some lady backs into my ft...Allstate's settling for $1200, just based on the broken up skin and a custom ft bracket used to hold a "TEE" bar rack for my hang glider...bent it a bit and cracked a weld...
Back to the back bumper, you D1 guys have it a bit easier...don't have to fill that recess on the rear 1/4 panel from the stock bumper...
One problem I'm having, maybe someone has some insight...I've built up a 2X4 and plywood mock-up, actually on the 2nd one, but appears that the body is asymmetric by 7/16"...off center...is Rover that slack about about body alignment? Or is mine just tweeked?

 

Yes, I had to wollow out the mounting holes on my after-market bumper to line up with the holes to mount it, and I have hear that is he the norm on lots of parts