On my overland the front driveshaft has u joints on both sides of the shaft, i have had 0 issues with the rc lift kit i put on over a year ago. No sure why awd models would make a difference, mine is awd. I have the 4 inch rough country xflex lift with steering stabilizer.
The bumper is 3/16, the winch plate and radiator guard is 1/4 the mounts are 1/4
as for mass producing weldable kits, not gonna happen i dont have the means to cut it out, i payed a shop to do that. The rest me and a buddy did.
I know you said you got it powder coated for free, but ask your buddy what he would normally charge for the job I'd be curious to know what this would cost me to do, I could weld it up but powder coating, no.
Great job. I have been on the fence with ordering the plans how much does this one weigh? Just a ballpark would be fine I run a fab shop seeing how my overland is silver I am thinking about building with .125 304 stainless instead of the .188 HR about to order a 3" ome lift from Kola but I don't want it to lower the front. I would also insert the round OEM fogs in the bottom. You did a great job!