One of the most common questions we get at Wide Open Design is: “What size links do I actually need for my rig?” And honestly, it’s a fair question. Once you start looking at aluminum suspension links, things get confusing fast:
- multiple diameters
- different wall thicknesses
- various thread sizes
- left-hand vs right-hand threads
- metric vs standard joints
- different vehicle weights
- different link lengths
A lot of builders know they want stronger suspension links, but they’re not always sure how to properly size them for their application. That’s exactly what this video breaks down. The video explains how to measure:
- jam nut to jam nut
- overall link length
- thread dimensions
- joint orientation
Watch the Aluminum Link Sizing & Measurement Video
Not All Aluminum Links Are Equal
One of the biggest misconceptions in off-road suspension building is assuming all aluminum links are basically the same. They’re not. At Wide Open Design, we exclusively use 7075 aluminum for our suspension links because of its incredible strength and memory characteristics. Unlike softer aluminum materials, 7075 offers:
- significantly higher tensile strength
- improved resistance to bending
- better long-term durability
- improved structural memory under repeated load
But even with the correct material, proper sizing still matters. You can’t simply throw aluminum links under a heavy buggy and expect them to survive if the diameter and wall thickness aren’t properly matched to:
- vehicle weight
- link length
- suspension geometry
- intended abuse level
That relationship between link length and vehicle weight becomes critical once suspension loads increase.
Selecting Diameter and Material
- The "Next Size Up" Rule: If you are unsure between two sizes, or if you are racing, we always recommend moving up to the next diameter. The weight difference between a 2.25" and 2.5" link is minimal, but the increase in structural strength is significant.
- Weight vs. Length: The correct link diameter is directly related to your vehicle's total weight and the overall length of the link itself. To help you choose, we provide a detailed selection chart on our website.
- Chassis Clearance: If your suspension geometry limits the diameter of the links you can run, call us directly so we can help walk you through the best technical solution for your specific rig.
Determining Thread Size and Pitch
- DIY Measurement: If you are replacing an existing link and don't know the thread size, you can measure it manually using a set of calipers for the outside diameter (OD) and a thread pitch gauge. For example, a common joint might measure 1.25" OD with a 12-thread-per-inch pitch (1.25"-12).
- Left Hand vs. Right Hand: You must identify if you need left-hand or right-hand threads to ensure your joints and jam nuts function correctly.
- Custom Threading: While our website features the most common thread options, we can accommodate custom requests—such as M30 x 1.5 metric threads—for a small setup fee. For custom work, we recommend sending us your joints to ensure a perfect machined fit.
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