AgDieseler, lets see some more pics of that skid/crossmember setup. looks like youve got a lot of work into it!
Lots of hours for sure - that healthy mix of laying under the truck and thinking, sketching several designs, mock up, tack, fit, adjust, tack, and finally settle on what makes sense.
What I arrived at was a modular crossmember and skid plate assembly - three independent crossmembers that hard mount to the frame, and the skid plate ties them together to act as a unit. To ease service at home and in the field, each component is sized so it can be removed/installed by hand without the use of a floor jack. I was going for simple.
Tube is 2" square 3/16 wall, because that's what I had leftover from another project, and the plate is 1/4". Frame mounting hardware is 7/16".
The front crossmember handles the mounting of the 4L80E, and has a gate cut out for the front driveshaft. This design is fairly common.
The middle crossmember is flat and handles most of the drivetrain load. It's mounted from the ORD Magnum-205 adapter plate via a compact clevis assembly and 2" poly bushings frenched into the square tubing at a spacing halfway between that of the motor mounts and the transmission mount just ahead. Since this would be the primary load bearing unit, it is sleeved internally with another square tube.
The rear crossmember serves as a tertiary mounting for the skid plate so any load applied from an obstacle is fully transferred to the frame and will not impact the 205.
David