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I don't know that I ever got as far as thinking about materials, and I haven't looked at those files in a while, but guess I might have used something like 3/16-1/4" plate? I wouldn't use solid for anything, except maybe an application where I might be concerned about tubing getting crushed...

Exactly. We're talking about radiuseses in two direction here. 1st is the shape of the plate if you were looking at it from the top/bottom, and 2nd is the front/back edges/corners of the brackets where the brackets contact the frame the framerails. The idea is to reduce the stress that's...

Just noticed one more thing: I still think it's a bad idea to mount this to the bottom of the framerails, but in any case, when you sandwich something between two plates, it's always a good idea to make the two plates different sizes/shapes. Would also try to avoid making those plates with...

Something like this. Could be built even tighter if it was custom (instead of bolt-on). Nut even if that's not what you're looking for, it's a great example of how you could go about having these things built (find a company that's already in the business of manufacturing receiver hitches and...

Yeah, I agree with JasonS. No reason you can't build a safe quick-release receiver hitch. Just gotta put a little more thought into exactly how you ought to go about designing/making it. I started designing a quick-release 3-point hitch after seeing some of the hitches that other members have...

Sorry, was trying be helpful, not to discourage you.

There's just not much strength in the center of a piece of solid bar, and small diameter bars are not especially strong in compression (compared to larger diameter tubing). Also would avoid drilling/bolting to the top/bottom of the framerails if at all possible (I don't think that's even legal...

Not going to gain much/any strength using solid-bar vs. heavy-wall tubing.