I went to the local steel yard, purchased a 24' section of 5/8 "grader flat" bar that was beveled on one side and was 1055 steel ($130), and then went to the local equipment supplier, purchased the seven shanks necessary for my 6' bucket and the six shanks necessary for my 5' foot skid steer bucket (@ $26 each), and used my Hobart MIG 175 welder to weld it all up. The steel yard chopped my 24' bar into the lengths I needed for $5. Five foot toothbar investment:
5/8" Grader flat bar - $27.08 (pro-rated)
Cutting charge: $2.50
Six shanks with pin-on teeth ($26/
ea) - $156
1/2"x3"x1' flat bar, cut 6" long on each side (side bolts) - $7
Grade 8 5/8" 2" long bolts with lockwashers and nuts - $4
1/2"x2"x2" coupons (2 required) for side strengthening - $2
Rust Oleum heavy rusted metal Primer - $2
Rust Oleum High Gloss Black top coat paint - $3
Welding materials - perhaps $3
Total: $206.58
Time spent: 4 hours
Fun rating: High
Six foot toothbar investment:
5/8" Grader flat bar - $32.50 (pro-rated)
Cutting charge: $2.50
Seven shanks with pin-on teeth ($26/
ea) - $182
1/2"x3"x1' flat bar, cut 6" long on each side (side bolts) - $7
Grade 8 5/8" 2" long bolts with lockwashers and nuts - $4
1/2"x2"x2" coupons (2 required) for side strengthening - $2
Rust Oleum heavy rusted metal Primer - $2
Rust Oleum High Gloss Black top coat paint - $3
Welding materials - perhaps $3
Total: $238
Time spent: 2 hours (I got better)
Fun rating: High
Worth it?
Not sure, really. I spent quite awhile in total, but firmed up my bucket quite a bit more than I would have with a lesser grader flat bar. Note that I do have "other costs" here as well - like the cost of my extra grader flat bar that is just now sitting and collecting dust (might use that for another project in the future - no telling) and the mileage getting all this stuff. I do have the eBay seller's referenced 1" shanks, but don't see a problem with them - I seriously doubt I'll be breaking those any time soon. One benefit of doing it yourself is certain knowledge that it will fit properly and the ability to avoid the bolts of a bolted on cutting edge. This, of course, all assumes that you have a welder. I did go ahead and do some beveling to ensure adequate weld penetration.
Good luck!
Ed