I ran out of patience and painted the thing. Made from 1/4" 6061 aluminum plate, centre section 3/4" thick. Got tired of cutting, welding, grinding, rinse-repeat, Not entirely happy with the end cap design, but again I got tired of futzing around with shapes.
I should have modelled in plywood instead of making things up in aluminum as I went along :-)

https://shufti.wordpress.com/2015/07/22/vanagon-front-bumper-build-pretty-well-done/

It's not a bull bar, that tube affair, it's a light bar. I'm still mucking around with my aux lights so I have yet to mount them on top of the bar. I'll post something about the lights and install soon.

Alistair