The problem with bumper design is not going so crazy that you add a ton of weight. I like your design, looks cool should you use a reasonable thickness of plate, and as mentioned, 1/16" is too thin in most areas. I'd likely go with a mix of 1/8" and 3/32"
While the popup lights look like a cool idea, in an offroad vehicle, exposed to mud and grit, simplicity rules the roost. You'll spend alot of time working up a design that will likely get gummed up with muck and rust down the road.
I've been in various engineering fields over the years, and have come to the conclusions that the best designs have zero adjustability. If something is designed correctly, it doesn't need to be adjusted, and there is less to go wrong. The simple design may appear obvious, but you never know how many itterations it took to get that way.
-------------------- '94 extra-cab 3.0 extra slo (auto tranny) original owner. E/B o/s valve heads and no more crossover. More mods to come.
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