Has the notched design for the frame extension that you're using been modeled in a finite elements analysis or other stress modelling program to prove it's strength?
Many people don't use sleeves and use straight cuts and butt-welds in certain automotive/truck circles.
Sleeved frame, rosette welds, UCA mount on top and the cross-brace next to that. Should be solid. As far as I know the Australian extensions don't do the UCA mount over top or use cross brace? I could be wrong. Either way, I think it'll be significantly stronger than stock.
Add in some welded-on side-steps/sliders, it'll be golden.
Spoke to Ian about the cross-brace while I was in ID. It'll be going in my Troopy as well. Does it need it? Maybe not. But as was said, suspension should be doing most of the flexing not the chassis (in most cases).
I'm the farthest thing from an expert though.
Last edited: