I still am interested in knowing what problem he is wanting to specifically solve with stronger knuckles. We don't see that often as a part that fails.
Though at the same time, an axle that is appropriately sized for a tire this large is also likely up come with larger steering knuckles by default.
Now that it may not matter as much, I know the exact weak spots on the factory knuckles and from a very odd place for one and a not so common place on the other. When I was buying cores for Vanco, I dug through a pile of about a 1000 pair that were collected from salvage yards. The #1 failure there is the steering arm being snapped on in collisions. The second failure is where the little shelf is we use to smack the knuckle off of the ball joints. I'll get a pic of that here in a bit to show why.
This is where they fail stock. Left is what we did to make it better. On a side note in reference to load bearing ball joints. No one with any engineering sense would look at that small cross section, overhung ear, and think that is a good place to subject to any vertical loads.
Thanks, 90% of what I do is learned through observation. The rest I depend on folks like you to keep me straight.
I'll see if I can dig up some more pics of what we did to help the stock design. It is surprisingly difficult to add material for increases in strength without affecting how everything has to work.
The obvious place to beef up is the lower part that is load bearing upward. If you increase the webs inward, they bind on the inner C. If you move them outward, they bind on the C the other way and then get into the rotor face. If you beef up the steering arm too much, the ABS sensor won't fit. It is ridiculously complex for such a basic part.