I have done many searches, but wanted to know from you guys what the best way in your opinions of strengthening the Uni-body on our XJ's. Specifically down the frame rails (tying in rockers), and steering box area. Just wanted some opinions on what and where the best way where steel is welded, what size steel plate, etc. pics would be great!

Check out the TOTM in the jeep bible.
http://www.pirate4x4.com/forum/showthread.php?t=168280&highlight=TOTW

What I did was bought TNT's 4 bolt conversion with the stinger bumper.(tntcustoms.com) Found an 1993 Jeep YJ Steering box on ebay and bolted it together. The rails got Rocdog's steel plates.(rocdogfab.com) The bumper and the steer box went together really nice. shipping with tnt sucked balls

The links above with answer just about all your questions. When it comes to overall strength of your uni-body you can plate it until you are completely sun burnt from welding and you can still twist the body fairly easily with some hard wheeling.

A cage is going to make your rigs structural integrity 10x stronger. Plating the steering box area and the sub frame is very important and gives you more strength for your rig overall but in my opinion you get the most out of plating for mounting purposes. Suspension, belly pans, sliders and so on.

Vette’s rig is a very good example for strengthening the uni-body.

Boatsides make a huge difference

Boatsides make a huge difference

Boatsides are also badazz! Roc dog is a nice way to go if no on the boatsides.

After adding bumpers, crossmembers, frame plates w/ steering box tie in, plus an interior cage i still bent my "frame", i would suggest some form of exo cage as protection to prevent the exterior damage you will encounter.

XJs seem to be especially vunerable along the roof pinch seam.

After adding bumpers, crossmembers, frame plates w/ steering box tie in, plus an interior cage i still bent my "frame"...


And you're probably what? another 500-600 pounds heavier?. I really think all the frame plating crap is more detrimental than helpful.

I agree that I likely have 3-400lbs tied up in my boatsides, frame rails, bumpers, skid plates, etc. But it is a hell of alot better then all my work going to waste because my body structure fails. They really do need the bracing when the size begins to really increase.

I would suspect poor suspension design would be a more likely cause of unibody breaks than larger components. Also things like wracking on the steering wheel when the tires are obviously wedged in.

And you're probably what? another 500-600 pounds heavier?. I really think all the frame plating crap is more detrimental than helpful.

Heavier yes but without the plates you have no protection, the XJ needs structural reinforcement to do what we do and even then its still a crapshoot. The steering box area is especially important.

I would suspect poor suspension design would be a more likely cause of unibody breaks than larger components. Also things like wracking on the steering wheel when the tires are obviously wedged in.

Poor suspension design can kill a rig thats true, however larger components can raise hell on any vehicle, there is no way an XJ could handle the weight of 60s and heavy rubber without some form of sacrifice, either weight or worse.