pic: 6WD base

[AdamHeard]

This isn't specific to this base, but more of a general statement on welded joints.

You can save your team a lot of heartache if you spend some time thinking about and analyzing the forces that are acting on the welded joints. If you can then design the joints so that weld alone doesn't take the stress from these forces, you'll end up with a much more reliable design obviously.

You're rear cross member is a decent example of this, the way it currently is an impact on it's rear will cause it to push directly onto the siderails. If the siderails extended past the cross member, and the cross member was between them, the weld would take the entire load. A lot of the times it's really a trivial difference.

I'd also advise you spend a little time learning about the different types/shapes of welded joints. Once again, a usually trivial change in frame design can result in a joint that is much stronger due to the weld itself being easier to do, or a stronger weld.