I took my old crossmember to the fab shop this morning – they said “no problem, check back after lunch”. I got him to bend 3 pieces x 43″ long. I called back after lunch – $50! – but they were ready. Once I got back home, I discovered that they used a little thicker steel, so the height of the channel was about 1/8″ taller – not really a problem, so I can work with that. He went ahead and used the full width of the sheet – 49″ also.
I began by measuring the length of the end tab and marking it with a square.
Next, I cut the tab out on both sides.
Then bent the tab down.
Lastly, I measured the total length of the crossmember, marked that with a square, and added 1 7/8″ for the tab – then cut to length. I repeated the process to create the other end tab.
I test fit it in place.
Then marked and drilled pilot holes for all of the various holes.
I came back and used various size bits to re create the original holes. I used a step drill bit to drill the 1″ hole on the drain plug side and 7/8″ hole on the other side.
I test fit it in place and realized that I didn’t cut the half moon out that goes around the drain plug hole. So I used my spare chassis to locate that so that I could re create it on the new crossmember (is was rusted away on the old crossmember).
Lastly, I test fit it in place one more time and drilled the holes where the rivets originally were. I WAS just going to put bolts back in their place, but ran across some carriage bolts while looking through my bolt bin. I think they look pretty close to rivets, and definitely better than bolt heads!
Tomorrow, the plan is to prime and paint the bottom of the tub (after I grind down those spot welds) and crossmember. Maybe if the paint dries fast enough I can get the frame welded back on the tub.