I've said repeatedly that years ago I put my LJ on a diet. It was an obsession that ultimately resulted in dropping nearly 500 lbs. The results were that the Jeep road and handled much better, stopped shorter, and accelerated faster. Most importantly, it was noticeably more nimble when climbing over obstacles. What I learned on the LJ is what inspired me to build my current TJ. It also taught me that my preconceived ideas about aluminum were wrong.It does matter, especially with the 4.slow. Static, it isn't a big deal. But 500 pounds on a typical built TJ is 10 percent of the weight. Once that extra weight becomes dynamic, it messes with handling, acceleration, deceleration, the shocks ability to control the body (meaning the springs will compress more for equal force impact).
Think about this, Rick. What do you think your doctor would say if you showed up 10 percent heavier than you are now...
Today, I would use aluminum for all the body and under armor. The only exception I can think of is the use of steel for the rocker slider. This is one of the reasons why I'm a big fan of the Savvy design. You get maximum rocker and body coverage with light aluminum, paired with a strong and, relatively inexpensive, replaceable slider. The one place I'd have a question about is where Savvy uses stainless steel for the upper tub rub rail. I would think aluminum would work, so my guess is it has something to do with the required bend to go around the corner. I'm sure Blaine can explain that one.