Pics are in my gallery. As for a write up, it's done of 1/8" aluminum. I was very fortunate in that the aluminum stock was similar to what you'd find for a drain pan under a home A/C unit. It already had the 90* bends in it, otherwise aluminum that thick would be a bugger to bend. It's pretty dang stiff. I did quite a few dry runs with cardboard before I started to cut the aluminum. Even so, I had to do some trimming on the aluminum after the cuts. It's not complete at this time. It's still in that bare form you see in the pics. I've put this one on hold until I find out whether the switch I'll use for the lights I plan to put on the bull bar are proprietary and necessary. Or whether I can cut the harness and use my own switches.
The switches in the pics are just your basic LED lighted rockers from action-electronics dot com. When I find out about the bull bar lights and can go further with this project, the plan is to cover the aluminum with some upholstery foam, then cover with a vinyl to match the interior. Should look pretty well finished after that.
I've told Smoke that I'd trace onto paper the outline of the piece as it is, I'll make that same offer to you as well. The dimensions will be off slightly because it'll be a trace, but it should get you a good starting point to do your own cardboard rough copies. PM me if you'd like me to send a trace to you as well.
