I'm currently putting a RC 44 frt, 60 rear under my XJ. Fabbing new crossmember for mounting of longarms. Thinking of using 1" ends with the 1.25 thread....should I use 2" od DOM with .250 wall or is this over kill? What are most folks using for link material? I've seen square tube...but ...???

1-5/8 1/4 wall you can tap for those rod ends. That is what I have waiting to be installed. 1-1/2 3/16 wall would work for that too if you wanted to go a little lighter. I know several people running the 1-5/8 1/4 wall with no problems so far. I would only try the 3/16 wall on a very light vehicle, the lower links are low, expensive and you are screwed if you kink one so it is a good place to go overkill in my opinion.

I am using 1.5 x .250 wall, with a nut welded on the end and tapped for implement heims.

I think the point above is key, if you kink a lower link (easy to do) you are screwed. My answer to this is to make an extra and leave it in the tool box in the truck, but I don't run competitions so its not such a big deal for me.

Foley

I'm using 1 1/2" d.o.m. .250 wall, 36" long with 2 1/2" jonny joints on my cherokee. build up (photos.yahoo.com/petehamann)

I ordered the DOM today, going with 2" o.d. , .250" wall and think I'm going to use the massive Polyperformance rod ends on one end and a rubber bushing at the crossmember. Hey Pete, have you driven that rig yet? I'm wondering how that having only one upper will hold up?:smokin:

I've been thinking of using 1.75x.250 DOM for my links.

With Jonny joints on both ends of the lowers.

I was going to see what would happen with an upper on piece triagle link with two spring eye type bushings on the frame side mount and a single big ol jonny joint or rod end mounted in the center above the diff housing.

Might not work out but I'm gonna try it and see how much the upper triangler link binds. The housing I have already has all the work done for a single upper link.