[hemi43]

I finally got around to making a push bar, but first must thank Yukon Jack and Lieferson for their help, because that saved me hours of work. Once I have a final design of the main bracket shape, I will offer a DXF file of it for anyone that would like it. This file can then be taken to anyone with a CNC plasma table or water jet.

The original drawing is very close to the final shape, but I want to tweak the area around the bumper so that it has more of an even gap. Unfortunately, this design does require drilling one hole per side into the frame rail. I will try and figure out a way to use the existing hole in this area, but by doing so it may make it difficult to install. Time will tell.
Here's a few pictures of what I've done so far. I first printed the shape on paper to make sure the scale was correct, then cut some scrap 18g sheet metal. The final piece will be cut from 3/8 plate.

I built my CNC table a few years ago using a CandCNC controller and an old Dell PC running windows XP and Mach3. One of the best things I ever built !! I can think of a part, and have it in my hand within 10 minutes.