body stiffening

Great info in this thread as always. 72bluNblu, you are a wealth of information, sir. Thank you again.

How are the US Cartool torque boxes in terms of fabrication/welding? Are they as big of a project as the subframe connectors? I'm thinking that these might be next on my list.

The torque boxes actually aren't all that bad. Most of the welding overlaps the frame rails, only about 1/4 of each box is welded to the floorpan. The rear boxes do overlap the rear subframe connectors if you use the US Cartool connectors, or wider tubular connectors like the ones on my Duster. Not sure how/where they would overlap the MP connectors. The welding that goes to the backside of the rocker is tricky, you have to do a lot of surface prep because the factory used some kind of coating on the backside of the rockers that does NOT like to be welded on. Zinc based stuff.

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--------------------------best and strongest way !

Prove it. I want either a 3D stress/strain structural modeling analysis, or deflection distance/degrees at multiple locations using a specified load and loading points with descriptions of where the loads were applied and how the chassis was held fixed at the other locations. For 2x2 tubular, US Cartool floor welded, tubular that doesn't go through the floor, and of course a stock chassis for a control, in order to demonstrate that 2x2 is both the "best" and "strongest" way to do subframe connectors. Obviously the same year/make/model car would have to be used.

Otherwise you're just guessing.