I have a 2001 Ram 1500 5.9L Sport Off-Road Edition and decided I'm going to build a grille guard for it. I want it to have full headlight coverage too. Does anybody have tips on making one of these?

 

Aside from the obvious "do you know how to weld", I would do some searching on the ol interweeb for grill guardsd and get some ideas on styles, shapes and sizes, then buy your metal and go to work.

 

If you're going for appearance, a simple bolt on style made from steel tubing works great. I prefer stainless myself, but it's a lil harder to work with. If you're going for function and durability, then heavy steel or stainless pipe or solid stock will be sufficient.