A few months ago I set out to design a set of frame mounted low profile steps that where strong enough to take a small hit, protect against car doors, use as a jack lifting point and protect the under body from perhaps jumping a curb that was a little too high.
these are what I finally ended up with...2x6x1/8" steel rectangle tubing with cut and reworked ends. the brackets are 1/4" plate cut on my CNC plasma and attached through the tube in 4 spots and to the frame in 3. They seem nice and strong and I plan to give them a couple tests.
Some of you have seen these in the works on another thread (which was deleted, and recently in the a sneak peek in the 4x4 section)
Pictures speak better than i can...
The Chassis Saver
The internal frame rust proofing
coated with a primer coat of chassis saver
than a top coat of black chassis saver
then some roll on Mostaliner bedliner on the top and side only
coated the brackets aswell