Re: New frame?? Need advice
Get some 2x3 or some 2x4 3/16" wall tubing and build a new frame. Find some measurements on the board (I know they have been posted before), or use your old frame as the template and build the sucker. You can miter and weld the bends and then put a fish plate at each joint to keep the strength. It sounds like the old frame is trashed, why bother with trying to fix it. If you paint a pile of manure pink, it is still manure. Why try to cover and patch something that is well past its prime. Besides a custom frame would be cool, and the tubing, especially the 2x4 would be a heck of a lot stronger than the existing frame. You could grind off and use your old hardware or buy it all new from someone like 4wd Hardware or Quadratec. Yeah there is a lot of fabrication involved, but think how cool it would be. And if you are thinking of any custom suspension mods this would be a great time. You would probably have to reuse your body mounts and maybe a couple of crossmembers and the rest would be your option to reuse or purchase new. I think it would be a great winter project.
Cage Up, Wheels Down
All my Jeeps are in pieces! Except for one!!