I started building new rear bumpers for our new service trucks at work and I thought of this thread. This design is very simple and could be easily scaled down for use on a smaller truck. Dimensions could easily be changed for different proportions as well.
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The box tube is 1/4" wall, 5"x10". Receiver tube is for a 3" hitch. The filler plates and bottom plate is 1/2" thick. The frame mounts will be 1/2" plate and notched into the bumper, with some gussets too. The forward portion of the receiver tube will be extended forward, to tie into a secondary crossmember that goes between the frame mounting brackets. Ends of bumper will be trimmed down and plated.
I think a 4"x6" tube with a 2" or 2.5" receiver would work very well with a pickup or Suburban.
