Just an fyi on that tubing. I have the exact same thing for my roof rack crossbars. The spread between supports across the rails is ~47". The bottom of the crossrail sits ~3/8" off the top of the roof. With me standing on the rack, jumping on the rails, they won't deflect to hit the roof, but they do deflect, up to about 1/4". They also have center rails running front to back, and so truly aren't even a full open spread.
My point? You may have issues with deflection when you come down on a rock. I'm sure the combination of 1/4" plate + the tubing will be beefy, but you might want to jack the truck up using the plate and maybe a small piece of tubing to localize the lift point (just be careful, you might even be able to find the true weight center and jack the whole truck up off the ground!). See if the plate deflects, because you don't want to find it's not beefy enough on the trail .
Pretty flush w/ the crossmembers.
Kinda difficult to tell, but there is about 2 inches between the transfer case and the metal.
You should be able to slide right over anything you can't clear. The exposed heads worry me a wee bit too, but it's just a wee, small worry
Rob (Ipedog - Say "Ip-E-Dog")
Black Sheep HUMMER Squadron
We will just make sure to spot you so the rocks you have to slide over go in-between the bolt head
I don't care about the "Jeep thing" as long as my mail is on time!!!
Slate Blue H3 Adventure w/sunroof, Monsoon/NAV, DVD and marker lights
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