Figured I'd share for anyone who may be interested. Built this tie rod for $200 (just the cost of parts). It's a 1.5" OD 7075-T6 solid aluminum rod, tapped for TRE's (LH and RH thread). Used the Barnes4WD TRE's over Ruff Stuff just because the boot is much better. To my surprise, the TRE's slid in without the need for reaming (or drilling/insert if that's your preference).

So yeah, $200 vs. other aluminum 1.5" OD options ($380 Carolina Metal Masters, $400 RPM Fab, or Fusion..although I'm not seeing their 1 ton bar anymore). For an extra $20 you can go with 1.75" OD rod (like the Fusion), but I wasn't interested in running the Rare Parts TRE's or making room for the thicker bar.

I chose aluminum over chromoly/steel because I have a tendency to smack my tie rod straight into rocks. I also like the shiny look and weight savings too . Doing my drag link next. In the meantime, have some bling:

 

How do you adjust the length for proper toe?

 

The left hand/right hand threads makes it cake. I just loosen the jam nuts and spin the bar.

 

You're only 200 miles north of me, when are you building another one??

 

 

Please excuse the basic question.....how did you hollow out and tap the ends of the solid bar?

 

How long is the aluminum section? What did you use to drill and tap? Link to the parts you used? Thank you. It looks great!

 

The rod was made-to-order from a fabricator who cut and tapped it. There are plenty of people out there who can do it, but I went with Wide Open Designs. Stinky Fab Offroad (lol) is also an option.

I went with 53" and it worked perfectly. More than enough thread engagement.

Tie rod ends:
Offset GM 1 Ton Tie Rod End OS2234L Left Hand
Offset GM 1 Ton Tie Rod End OS2234R Right Hand

 

So the $200 is all inclusive of the cost of the rod and fab work?

 

IDK if you've gone and looked at the website since posting, but a 53" bar prices out at ~$115 for 1.5" diameter, and that includes having the ends tapped for TREs. Then buy the TREs, pop em in, and a SS clamp if need be, so y, looks like ~$200 all-in