Thanks so much for everyone's advice and suggestions!
I'm going to start looking into materials soon...

Icysyrup, did you mount your plate for the trans/transfer case from the cross-member? Did you install mounts for the attachment towards the rear?
Is there any way you might be able to post some pics of your handy work?


'02 Montero: OME suspension, ARB front bumper, homemade skid plates & spare tire Blitz can mount, extended diff. breather, K&N air filter, Optima Yellow Top, BajaRack, IPF lights, Goodyear Duratrac 265/75/16's, RUD 4x4 Grip chains