| I had the same problem, and fixed it with a piece of steel pipe. This piece of thick-wall pipe had a diameter somewhat bigger than the original crossmember, and was about 1 feet long. I have cut this piece of pipe in two (in the length), giving me two 'shells' of steel pipe. I then shortened the crossmember somewhat (to remove the rusty ends), and welded the shells against the frame so you have two 'hangers' to lay the crossmember in. The only thing was then to weld the crossmember to the new pieces of pipe, but there was no need to completely reconstruct the original crossmember.
The only issue was that at the drivers side (where the exhaust piping is run), I had to weld the hanger upside down, in order to clear room for the exhaust. But the crossmember is as easily attached to this upside-down hanger by welding, as it is welded to the new support on the other end. And it was a cheap solution.
Good luck,
Dieter
'86HJ60 diesel |