I went on line and found a site that calculated deflection on tubing.
I had already made lower links in.25 DOM and bent those
Running the numbers on that site made it clear that solid rod was the way to go
Add to that solid rod is cheaper. The over sized ends I put on help with protecting the frame and axle mounts as well as strengthening the weld joints at the ends.
I like the round stock over square. The LCAs are basically a slider and my thought is that the contact patch resting on a rock would likely be smaller than it it was flat
So I’m making some assumptions that you are using 1018 1” solid rod and DVS 2.5x1.5 .188 square tube in 1018 steel.
I’ll be frank, a 2” solid 1018 steel link on a 6000 lb cruiser doesn’t remotely meet the minimum factors of safety calculations if we include dynamic amplifications of loads from off-roading. (Offroad = Rubicon like trails)
Your .25 DOM bent and failed because it would need to be 3.5” diameter to meet minimum factors of safety. Jeeps (2-doors) can get away with .25 DOM because their links are shorter and they weigh half as much.
No one is saying that your links aren’t “strong” or “strong enough” in some applications just that others are.
The DVS links are stronger for bending and buckling and yield.
To your point about cost. You can spend $500 on a set of links from either company that both fall short. Or you can spend $400 on 7075-T6 that exceeds all of them.
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