I am going to run 2" round for my lower link bars and they will be parallel with the ground when layed out. there will be a bend when it gets closer to the axle. my question is how thick does that bar need to be if i dont want to run a gusset?
are you putting a bag on the bar??? if you are you need to gusset it or sleeve it with another tube no matter what. if not 120 wall is normally fine if its DOM.
I think that if you were to run 2" x .188 or .250 4130 you wouldn't need a gusset. Do a bit of homework on welding heavy wall 4130 fist. If you are concerned about the procedure, you can use 2" x .250 DOM and not worry about it.