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the corners are already on the truck you just need to fill in the middle. Cut off the frame horns and get some sheet metal and fab one up. I have seen several trucks were they have done this.
Before doing this mod check the DMV in your state. In most states a front bumper is a mandatory requirement. No front bumper will generate an inop and impound.
Plenty of room to put a bumper behind the rolled pan and welded to the frame rails..... Then, just like on the new cars, the rolled pan becomes the bumper cover....
or, if you prefer, a nice looking set of nerf bars ahead of the rolled pan....
old blue, you can buy some round stock and tack weld it to the existing corners, like 6-8 different pieces going all the way across the truck. i would probably have a brace in the center as well. then you can just take sheet metal and tack weld it to the round stock. It wont be as nice one rolled but some body filler and i think it would look great. ive often made aluminum pieces this way using ribs or some other form and pop rivet them together.
here is one that was made in several pieces
i love the hidden headlights on this truck
you could also push the bumper back a few inches and paint it like this green truck, but he blended it into the body i think
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.