Another bumper I built. Search for the build in the Offroading forum.
If you are planning on running a winch, you'll want to have the frame mount come straight out and attach to the cradle. if you using tubing or have bends to go around the bumper, you run the chance of bending the bumper, especially when your approach angle isnt straight on. Yes, you can gusset the hell out of it, but that will defeat the purpose.
if you plan on making a full bumper, 1/8 should be the thinnest you should go depending on how many bends, or gussets you have. Like on the bumpers I built, the corners dont have any more than a foot wide. The center part was about 40" and that should definately be 3/16.
I gusseted all four corners on both sides, and onto the hitch. If you are running a hitch, or winch, anything that connects to those should be 3/16 to 1/4 with gusseting.
Lightbar, I used 2" thickwall piping. Grille guard on the first one was 3/16(the the bumper is 3/16) with 1/2x1/4 flatbar around the end. The diamondplate was 1/8 and it did move a little.
I also build a grille gaurd for a chevy. 1/8 with that 1/2x1/4 flatbar around the edge and the owner says the lights shake a little going down a gravel road. That is because it wraps under the bumper, like you have drawn up 9.ford.5
White Max- Nice truck! What lift and tires are you running? I like the look of your truck alot!
I have a set of 2" lift springs on the front, though those were mainly just to level out the front of the truck with the rear. The truck currently has a set of 32x11.50-15's on it. I'm looking for a set of 33x12.50-15's.