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I know exactly what you are talking about for strength along those welds. I know what you mean about welding on a plate at the ends of each tube before welding the...err..tubes together. Was thinking about that earlier.

Frame flex is a major issue with something like this, I agree. Its something I struggled with when making the Exocage for my Unimog. In the end, as best as I tried, I still sacrificed some frame flex, but that was fine with me in the name of safety. Ended up using bushings at frame joints. Added...

I read through, maybe I missed it, what does anyone think of this design posted previously? Obviously a heavy wall material, maybe 1/4" or more. I am in the process of working on a ROPS system, I want to use 2.5" .250 wall DOM, but am still working leads on finding someone to do the bending...