Having gone through this process myself, I can offer this advice:
1/4" might be thicker (heavier) than you want. Mine is 3/16". ARB's are 3mm I think (Which is less than 1/8" thick), but it has tubing reinforcement (per their site). If I were to do it again, I might even go 1/8". Mine is currently 3/16" and I've never thought "I wish I'd made that thicker". The brackets on mine are 1/4" 2"X2" angle steel.
Troy is right, to weld 1/4" you will want a 220v to do a good job. I did my 3/16" bumper with a good 110v, but I welded both sides because I didn't like the penetration. You can get buy with 110v on 1/8" and maybe 3/16" as long as it is a good welder.
I recommend a wire welder because they are so darn easy to use. The flux core is fine, it will just take a lot of work to clean it up. The gas will allow you to just weld and be done once you get good.
Arc welders are cheaper and will do a great job once you get good with them, but not as easy as the point-and-click wire wleders.
If you can afford it, get a cheap plasma cutter. Even a harbor freight 40 amp for $550 will work (that's what I used). I wouldn't expect it to last for years, but mine has paid for itself already. If it dies tomorrow, I got my money's worth out of it.
If you go with a wire welder, don't cheap out. The smoothness of the wire feed makes all the difference in how easy it is to use. Cheap ones don't cut it. Don't get an HF welder.
Mock up the design using foam board from a local hobby shop. You can buy it in 3/16" thicknesses so that it will be the same dimensions as your steel. Cut it, tape it up, etc. Then use it as a template to cut your steel.
Boiler is right that this will take MUCH more work than you think it will. I would do it again ina heartbeat, but only because it is mine. I have a lot of respect for Marty and Boiler who do this all the time. I have had people aske me to make them a bumper and I say, nope. I'll help you make one, but I couldn't sell them for $2000 and make it worth my time.
The steel for front and back bumpers on mine cost about $250.
Welder (used) $350
Plasma Cutter $550
Grinder, Sawzaw, wire $250
So you can clearly see that I probably could have bought a rock lizard front and rear bumper, especially when you consider the 40 hrs or so of labor that is not included. I wanted a welder and plasma cutter anyway, so it was the right thing to do for me, but it isn't for everyone. And even though I really like my front bumper, the RL rear bumper looks a lot better than mine.
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