I wanted to extend OEM flares and keep the original look. So I had 1” rubber Water jet cut out to the profile of original flares and bolted them on with longer bolts.
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You are right the original design in steeI would be excessive. However I was planning on using 16 Ga sheet metal with inner and outer flanges for mounting. They would actually be lighter than the Rubber ones.I think steel would be excessive. Maybe make it out of perforated plastic. Or solid plastice and drill a bunch of holes to lighten it but still keeping rigidity.
I'd like to see the 2" steel when you are finished. ThxI realize the X2/X4 aftermarket is alittle thin. If I can get this figured out I would make more. I am leaning towards making 2" wide extensions. I miss the Tree Kickers on my R-spec and want to make some of them also. If you noticed the new RMAX1000's have them again