I'm sure it's been done, but there are dozens and dozens of companies offering grille guards and light bars. Are there specific issues you need resolved by your light bar that aren't generally offered by the commercially available options?
A custom built option is going to have a custom price--that is, it could be any amount depending on the time that went into it and the competence of all involved.
I think I'm going to go with the ARB JK Stubby bumper. I want a stubby bumper anyway and the grill guard is close enough to what I have in mind. The price is $600 which is reasonable, especially considering the cost and variable results of trying to go with a custom solution.
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