Rather than cutting the entire crossmember out, how about just sectioning it? You can make a simple scribe tool by tack welding a center punch to something that will hold it the correct height relative to the crossmember (say, even with the bottom of the A-arm?). Then just slide it around the crossmember and scribe a line all the way around. Get out the cutoff tool and cut the bottom off, then template it and plate it back in.
IMO, that would be better than replacing the whole thing with a piece of heavy plate...
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Ray Kaufman-Wyotech chassis fab instructor
Custom suspension design and consultation.
(Now 2) Big Block asphalt supermodified ('cause too much is never enough...)
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