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[chicago]

I'm not seeing the reason for bar stock either Chicago. You want as much depth in the material as possible. Why couldn't you have only used some 2x2 or 1 1/2x 1 1/2 box in say the 1/4" thick variety? The ends could be bent up and coped with you're tube frame mounts, and you could drill the tube out for the bolts, and even recess the bolts through the tube. Seems much easier than welding a bunch of box to that bar. If this doesn't make sense, I can sketch it out for ya....

Now that ive gone this route, I certainly could have done the same thing with some square stock, which I have.
Just couldnt quite see it at that point. As far as moving anything UP into the frame...that is NOT and option. The flange interferes with anything above the level that its at.
Its not too much extra to weld some sqaure stock on that. I think it will be okay though. For some reason...this was easier. Donno.

 

[chicago]

To update...Here's the finished product...
I think it'll be good to go.

 

[chicago]

And yes, I did grind down the through sleeves on the bottom.