I've not made mine yet, but i am going to - everybody's got to have some vapour.
160x80x4 box section, with the ends cut out, bent up and rewelded to the same angled profile as a standard one. I'll plate the ends up as well.
drop some tubes in for tow ball bracket, and those needed for my mantec wheel carrier, and pretty much leave it at that, I don't need anymore holes for mud flaps, jacking socket etc
I'll probably make some chassis extensions from 3mm plate, and probably let them through the box section. some off-cuts of the corners of the box section to make the tub brackets, an exhaust hanger to make.
I looked at the cost of a 6m length, it was about 100 quid i think. If you could make three and sell the other two, that's pretty reasonable.
Shouldn't this be in tools and fab?