The cross section of those frame rails is roughly 3"x3.625". I can get standard ERW tubing in 4x3, 3.5x3.5, or 3x3 sizes. Gauge varies, 11 or 14, depending on the size. I'll have to rip everything off and see how hard it would be to replace the rail with a chunk of tubing, maybe retaining the top surface of the OEM rail to maintain some of the mounting points for the under hood stuff. At least if I try it this way it won't be costing $1000 in parts. I'll see what a custom bent piece of 11 gauge will cost too. A simple U-section welded to the current top piece might be enough. Feeling a little better as I think about this some more.
A question for the horde.....does anyone know if the sway bar mounts are just bolted to the frame rails, or are they bolted and spot welded? I tried to get one to break free after the bolts were removed and it hasn't budged, but it may be rusted in place,too.
