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Strength comes from form more than material thickness!Mines got everything from .120" wall to 3/8".It took a week to form fit the radius of the front grill! Front Bumper Pics
Thanks!!!It turned out really well,it weighed about 50lbs. and is really strong!You can put a high-lift under the ends of the flare returns and pick-up the entire front end(the offset/staggered joints provide alot of strength at the corners).Its taken some pretty hard "rock smacks" with nothing more than paint damage!
BTW:the overhang/approach angles are awsome,its only 2" deep by 6"high!