Ok so I'm building and installing full lenght frame rail reinforcement built out of 3.5"x3.5"x.250" angle iron. My question is what are most of you guys doing for mounting the reinforcement you have? Stitch Weld, plug weld, or lots of long bolts through the new metal and sleeves in the uniboldy rail? Post what you've done and why and a pic if possible. I'm leaning towards stitch weld and plug weld. Thanks and hopefully I put this in the right spot. And ill post up athread in fab when I'm done.

 

Weld it, don't bolt it. Make it an integral part of the frame or you're not gaining as much benefit over the long run.

I've read and seen pics of everything from 11ga to 1/4". General concensus is that 1/8" is plenty. If you're using angle, 3 x 3/16" is about the smallest you'll find commonly. If you have the 1/4", go for it.

I've got 3 x 3/16" angle in the garage awaiting some drilling and cutting to make mine. I'm planning to alternate plug and stitch welds on both flats/edges. If it goes smoothly, I may end up edge welding it completely. I'm also adding some extra nuts on the bottom to attach a new crossmember for the front 3-link, but that's another subject.