Without a bender.. it's not gonna happen unless you want to make it with angled corners. I'd find a welding/fabrication shop in town and tell them what you want. I had my front bumper made for $300 out the door, that's 2"x0.25" DOM tubing. And it's a bumper, not just a "light bar" or "brush guard". It's totalled a car and I pull from it.
http://memimage.cardomain.net/member_images/9/web/597000-597999/597075_39_full.jpg
http://memimage.cardomain.net/member_images/9/web/597000-597999/597075_39_full.jpg