I'm trying to be realistic. The vehicle will weigh around 3,000lbs by my guessing (it only weighed 4080 according to title) and it'll gain a truck cab and narrowed front. The bed will be small and reduced to angle iron and either wood or "expanded metal" grating. I think I can hit the 3,000lb mark. I can get to 3700lbs on a longbox truck so the K5 fully loaded should be down to 3,000lbs without me in it. It should be even easier to hit if I can scrap the TH350/NP203 for a 700R4/NP208.
There will be no hydro assist.
Toyota parts are more girly than Chevy parts and they survive 38s.
I am not doing rockcrawling. I don't plan on going bigger than 38" rubber.
Keep in mind that most of you guys are steering a rig that weighs what mine will with a Jeep strapped on its back. Most of you guys are trying to move around in the rocks in the 5,000lb+ neighborhood. Remember, the front of the truck is actually going to be lighter than stock. It'll gain a narrowed front, batteries moved to bed, and no winch in the front.
The "weak" link on stock 10 bolt steering seems to be the stock rod location on the passenger knuckle. Flat tops have all that beef in there so I suspect putting the tie rod up high won't hurt anything there as far as strength. Then I don't think the crossover part is any harder on the passenger knuckle than a stock driver knuckle with push-pull sees.
Now we're to balljoints. The driver's side upper balljoint already gets tortured by push-pull steering and with a raised steering arm it's even worse. Now we're essentially moving it to the passenger knuckle. Then there is the histeer part that also loads the top balljoint more but only in the essence that both balljoints are now getting tortured instead of one.
I bent my stock tie rod (80s tube type) yesterday towards the passenger side of the differential. Bent it right into my differential cover. I don't know how a "rock rod" would survive that unless it's one of those fancy-pants rods that spring back into shape. I didn't do it on a rock either. I did it on a stump. I didn't even hit it hard enough to feel like I hit something. I thought I just got stuck on my front differential. I was idling in the mud getting off the trail so a Toyota could get by. I've never seen a 3/8" thick axle tube get bent or dented that didn't see a VERY hard impact.
Since with your guys' help I now know I can buy thread inserts and then can weld up my own links that's what I'll be doing. I don't know how that can be any more "beefy" than stock since it's still DOM mild steel. Probably still bend just like my stock one did.
Got any pictures of bent/broken/ruined histeer/crossover stuff on a light vehicle?