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Scott, since you're talking about flex, there's a popular upgrade being done right now by a lot of members of this site. It involves adding to or replacing the single cross brace under the gas tank. There's another pair of mounting holes ahead of that bar that can be used for an additional bar or a stamped steel Envoy EXT brace (#15076943) that seem to increase chasis stiffness. You being a metal shop I'd just build an X-member out of moly tubing connecting the 4 holes. Also, I believe, on 05 and 06 models they added an X brace under the engine too. I've never looked under an 03 or 04 to verify this, but one of the SSR engineers claims that is true. Also, you could do your customer a huge favor while the doors are apart and ask him if he's ever had interior door handle problems. The inner pivots are very thin plastic and break very often. There's an improved part and a TSB from GM on them. If you search door handles, there's tons of threads about them along with the updated part #s.
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