I believe mine measure around 84" just to give you a reference. Im running stock flares back on the front now. Basically the top edge at either end of the rail is just before the screw at the bottom of each flare.
I used four outriggers and angle iron to weld the rails to the unibody. The angle iron was used to plate the unibody rail in the four locations where the outriggers are welded. Each outrigger is was welded at slightly different angles to give some triangulation to support weight in both direction.
Bolt-on sucks in my opinion. Welding is the only way to go for strength. And I don't own a real welder either. And I never advise attaching to the pinch seam. If I had any steel left in my rockers (which I don't) I certainly wouldn't ever weld or drill into them. That's just inviting the red scurge to remove them for you later on. All you need is a whole mess of 2x2 square tube with a 3/16" wall. Cut your lengths and hold them up to the truck where you want them. Then take your measurements (every runner wil be a slightly different length) and cut 3 or 4 runners per side (the more, the better). Use some 3/16" plate (or the aforementioned angle iron) to spread the load out on the frame and then drive to a competent idividual with a decent welder (the frame is still just sheetmetal and it takes a certain skill to weld thick metal to thin). Clean up the frame and weld away. The only tool you need is an electric angle grinder and cutting, sanding and grinding disks for it. It's a lot easier than you may think. Mine is essentially an elaborated version (went through the frame for the ultimate in strength).
Jeep on!
--Pete
well, I probably will have them welded eventually. But I have to be able to bolt them on so I can get there. I don't know. Right now I'm in a time crunch before WF, and it was the best option. Poor planning on my part, but getting married in Feb kind of made it had to get truck parts together and on the MJ.
I totally understand deadlines (mine were installed the weekend before I left for Moab), but having to redo mods sucks a lot (especially if they fail or ortherwise cause harm). As a wise man once said: "Build your truck right the first time".
Jeep on!
--Pete