How thick metal you planing on?
I am really looking for off the shelf, but can't find anything for the 03 to 06 Models. I have seen a couple bumpers I like, the one with the 4 inch tube with 3/16, 3/8, 1/2 inch metal depending on location and if its actually structural or cosmetic.
I am going to price it out first plus see how bad my welding skills are since I haven't done any serious welding in 25 years or if any friends that weld are interested in helping. There are a couple metal shops in town that I can order the cuts from, then I have to weld it all up.
My father's next door neighbor works at Ryerson and one of the guys I go shooting with works for Phoenix Metals, both companies should have whatever I need and/or be able to point me to a local source for small orders.
If I don't do a full bumper, I am really leaning toward Sterling Equipment with their winch grill guard setup.