I posted this in the CJ forum, and figured I'd post it here for some other points of view. Forgive the double post.
I figure I'd throw this out for suggestions before I get to the point of no return.
Here's my plan. I cut out the bad part at the spring hanger, and made a patch piece from a hunk of box tubing, 1/8" thick. I want to keep the outer rails looking nice and smooth, if at all possible.
I plan on welding in the piece, then cutting out the inner rail to repair it. I have thinner wall tubing to make a piece for the inner rail.
Once I cut the inner rail open, I plan on fish plating the outer rail from the INSIDE.
The green was my plan, the yellow at the top if needed.
I can then close up the inner rail, and fish plate that, if it's needed (?). I can then grind the outer rail smooth, if it will be strong enough.
I've never done more than slap on some patches, so I'm turning to the guys that have done it before. I want to do it right, and not have to second guess myself.
This is just a rough fit.
Am I on the right track????