Time to get this thread up to date. Made up some cowl steps a while back. They won't be used as a step, just a support bracket for the rear of the front fender. The mounting flanges and the outside edge are 1"x1/8" flat bar that was laying around. I formed the radius by hand-bending around a piece of 1-1/2" pipe, until I was happy with the look. The top is 14g sheetmetal. The step is also going to be bolted on to the outside of the aluminum armor.