The most difficult part of the catcher mask design is filling the space between the front of the frame horns and the grill without encroaching too much on the front of the tires. Too one dimensional and the bumper looks like you bolted on a headframe to grandmas bed. The Three dimensional bends become more difficult to maintain consistency as the variations in tubing from batch to batch will result in changes that need to be adjusted for that need to be addressed with each new run. Having a fixed setting on a bender or even a press brake doesn't mean you can run the same exact settings from batch to batch. Two inch .120 wall HREW tubing has allowable tolerances of +/- .006 by acceptable industry standards which means your OD can vary by .012 and the wall thickness ranges from ~.114 to ~.122. This doesn't sound like a lot but a 90degree bend at a particular setting on a bender may yield an 87 degree bend with the next batch of steel. So bottom line is the most economical way to build a bumper like this is in batches. I'll start researching the project and try to find a solution. It may or may not be at 2001 ARB prices.
