I have a 2003 F250. I want to remove my grill and cut it up to accommodate a 34" LED light bar.

Behind the grill there are two C-channel type supports running vertically from about the bumper to the top of the header.

They seem stout but they aren't really all that big. Maybe 1" or so wide.

I want to drill a 1/4" hole in each one and bolt on a piece of 36" 3/16" thick C-channel steel, where I will then bolt on my LED lightbar to.

I would guess both the lightbar and piece of C-channel weigh about 8 or 9 pounds.

Do you think mounting in this fashion would cause any structural support issues or bend them over time? I'm sure going down the highway it would be fine but I'm more concerned about bumpy roads.

 

It would do it, but it would be pushing the limits of what I would mount to the header panel. See if you can fashion a bracket to mount to something metal