I'm designing these lower links for this project. They're kind of unique in that the lower shock mounts are 2" ABOVE the centerline between the pivots. I've designed them this way for improved ground clearance because this is a dual-purpose 4WD vehicle. After doing a bunch of research (here and here), I've decided to use stabilizer links like these to keep the links from flopping around(this image is of a vehicle designed/built by Drew at Poly Performance); except my stabilizer links will be coming from the center of the vehicle out to the links. Target weight for the vehicle is under 4000lbs, but it will have a functional bed and I will carry heavy loads on some of our off-road trips (maybe two dirt bikes plus gear).
The lower links I've designed are 47.75" long, and the suspension will cycle about 26" of travel using 16" coilovers and 18" bypass shocks (mounted 28" & 34" out on the links from the chassis-pivot). I'm planning on using 1" uniballs up front and 1 1/8" heim-joints in the rear. The tubing is 2" x .250-wall. The inner side plates are 3/16" and the outer side plates are 1/8". The interior gussets and top plates are also 1/8". The shock cutouts are based on the actual clearances that I think I'll need, taken from 3D models simulating the shock positions at full extension and full compression. I shouldn't need to provide for more than a few degrees of misalignment from side-to-side. SolidWorks tells me that each link would weight 32.3lbs.
I've included some links to the CAD files (native SW08 assembly file & IGS) in case anyone wants to run them through any type of FEA. I have a copy of COSMOSworks, but have not really gotten that far yet (still getting a handle on SW). I've also included an eDrawing file for those of you that don't use CAD programs, but might want to download a 3D file to check out. You can download a free copy of eDrawings here.
FILES TO DOWNLOAD
SolidWorks (08) assembly