Oval, I've been thinking of a solution to this and think I may have a way to do it. However it'll add to the cost which is already overrun. But if the customer wants it I think I can provide a solution.
There's also the option of dual center bars. I think cost and weight it might be a wash.
Personally, I'm going to replace the grill. I think the single clean bar looks the best, maybe with a stainless mesh grill. I'm open to suggestions.
My father said he wants two vertical bars in the center. I guess there's options here for the customer.
Tight fit. Yes I agree, too tight. However, having said that, I found a tighter fit than that between the bed and the cab, that's factory design clearances.
Also, our jig system was such that the bumper came out more square than the truck was.
There's a good spot measure on the front end (cab to frame) and we found it 3/8" out of equal side to side. Loosened the cab bolts and adjusted the cab perfectly evenly to the frame, suddenly the bumper fit perfectly.
I still grant you the design is a bit too tight and needs another half a finger's width clearance in one spot. The rest is dead on now.
Time frame, I think I can get the first batch done in 8 weeks.
We will produce bottom only variants and cost will be a lot lower on those. There's just a ton of time in fabrication in that upper. And the wings and center bars...omg, so time consuming. So much detail.
Finish, I think my favorite finish is going to be 'raw, let the customer finish it'. There's a number of advantages to this. Shipping, if it's finished it'll have to be bubble wrapped and crated, this will add a lot to the shipping cost compared to banding it to a pallet. This will allow a 'test fit' before the final finish is applied in case anything needs adjusting. I think paint or chrome will yield the nicest results because there are fillers for both those processes and none for powder coat. Getting the raw metal to have a perfectly smooth finish will be nearly impossible. I think with paint you can just 'wipe it' with filler on all the welds very quickly and get nice results. IMHO a good quality paint job will last every bit as long as powder coat. Color matching with powder coat is just not there. I've heard some people say you can color match with powder, I've talked to several places and they admit the process is just too different from body paint to expect a good match.
cost...it's going to be half again the highest prices are I've seen for bumpers for the full out mack daddy hidden winch bumper like is shown in the above pictures. I know I stated my goals were sub $2k range, but it's just not happening right now with this level of fabrication. Maybe I can simplify the design to reduce cost. I did it with my own two hands, I know what it took to build.
Don't worry folks, I'm a perfectionist and if nothing else, I can promise you the very best quality possible for your dollar.