Bottom of frame was mostly gone so I started with a piece of 3/16" x2"x6' and fed it all the way up the frame channel after I cleaned out the C-ment and removed the bolts for the bumpstop.
I actually cut more out of the frame to gain access to the frame hump and bumpstop bolt holes to be able to weld the plate inside the frame rail, & also bolt it via the bumpstop and hitch.
Welding & bolting = muy muy fuerte!
The end of the rails where the bumper attached was very thin, welding this part was terrible. and I couldn't get a grinder in there.
So glad I wasn't using FLUX core, as cleaning that would have sucked! Welds look like chicken poo but try welding a soda can to an I-beam once
I also used some angle to give me more steel to weld the plating on the sides (also 3/16)
I didn't need to plate the top as it was still in good shape.
once the bottom was welded I just boxed the frame with 3/16 plate and sealed it up with POR-15; this was completed over a year ago and is holding up fine to towing the boat, wheeling, and the highway.
I'll dig up some pics of it complete soon.
Mike