Rookie Team Passing Inspection (video)

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popnbrown --
We thought the same thing, min 8 inch bumpers -- but ready [R27] carefully:

[R27] Robots are required to use Bumpers to protect all exterior vertices of the Frame Perimeter. For adequate protection, at least 8 in. of Bumper must be placed on each side of each exterior vertex

The "exterior vertex" refers to the chassis (interior bumper vertex) and not the outside of the bumper. To overlap the side bumper, our front bumpers had to be min 10.75 inches.
Also, the 8 inches cited need to be fully supported by the chassis/frame perimeter. Inspectors said it was permissible to essentially extend the frame by 2 inches using a piece of stock aluminum mounted to the existing chassis and then mounting that to the bumper.

We never saw any rules defining maximum letter sizing and bumper sturdiness either.