I actually made this a few years ago but I never posted pics and I forgot to take pics during the construction. It's 2" box 1/8" wall. this was the first project I did with my home center special stick welder.

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[Linked Image]

[Linked Image]

[Linked Image]

If I had to do it again I would cut the end of the frame rails so I could extend the lower portion of the bumper another 3" toward the outside. Also after I had it mounted I realized that it wasn't far enough to the rear so that could step on it when the rear door was closed so I added another 1" in depth with a piece of 1x2 channel.

'96 SR, 35's, body lift, arb front bumper, Custom rear rock bumper, rock sliders.
'89 Raider V6 w/ SR rear axle & locker
Kirk's Montero page but not updated in forever
KJ6GVJ