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Any Idea what size the threaded end of the LJ rod is? I suggested to the suspension guy that I should get 15mm extra thread put on the 120y rod to allow for whatever adjustment I want, but he reckoned that it would be way too weak. Based on that, you would want the LJ threaded section to be the same diameter as the datto non threaded section...... pretty damn fat
I can almost guarantee that the LJ rods will be strong enough. I have them in my rally coupe and the front end cops an extreme amount of pounding and I have never had one fail. I cant remember the exact Dia sorry, but they are big.
I suggest that your suspension guy was correct about extending the thread on your existing rods. The standard rods have the threads hot or cold rolled during manufacture (very strong). You have suggested extending this thread by either screw cutting in a lathe or using a die. This actually weakens the thread and therefore the rod and your suspension guys has probably seen enough modified ones break to be kind enough to inform you and save you any headaches in the future.
*EDIT*
The LJ ones have enough thread length to allow plently of castor adjustment without modifying any threads. Their final position is fixed by a large nut and washer on both sides of the front mounting point so there is no fixed shoulder to worry about. Super strong and adjustable - what more could you want