Front cross member...bolt or weld?

I have a '66 CJ5 that a PO has "frankenstien-ed" the front cross member.
At this point, I'm going to cut it out and replace it with some square or rectangular tube.
My questions:
1. Would it be better to box the frame and weld the new cross member to that?
2. Not box the frame & weld the cross member to the frame web & flanges?
3. Not box the frame & bolt the new cross member to the frame web & flanges?

Or a combination of these three choices.

Thanks,
Lee

 

Sorry, not the tranny cross member, the front (below the grill).
The PO installed a Ford V8 and cut the top half off it and welded an angle onto the remainder.

I'm going to go with a Saginaw box, so instead of modifying (again) the cross member, I'm just going to start new.

Lee

 

You don't need to modify the stock crossmember to do saginaw.

 

You're right, I should have clarified my plan.
I want to sleeve the steering shaft through the front cross member to keep the box as high as possible.

Lee

 

I assume that you say "box up high" you mean the steering box....

Do you box the frame (weld a piece of 3/16" or 1/4" flat to the inside) and weld the member to that (the inside face)?
Or do you just make the member go all the way to the "upright" (outside) leg of the frame?

Lee

 

Looks like you used a combo of both weld to the boxed frame and weld to the "upright" frame leg.

I was just wondering if bolting the cross member in would allow the frame to flex just a little and prevent cracking. The old cross member is riveted in.....

Lee

 

The reason I always question this is that the AA mount gains you 1 1/8" in height over a standard setup like mine. Not really much of a gain for all the work needed, especially when you consider that the drag link is still hanging down the same distance to get caught on what ever. I have never caught my box on the 1st thing in the 3 1/2 years I have had it done, the springs and shackles would be ripped loose or dragged on 1st.

 

Would you like to have a crossmember look like original one? I found one from the engine cradle of a Chevy Asto van. I just cut the section out of the middle.

 

That's a good idea, but this project is far from "stock".
I will have to make an "L" shaped member to get clearance for the new radiator.
It's also going to be moved forward an inch or so because it looks like the fiberglass body and fenders are a touch longer than the steel body was.
With the SB Chevy (V8) in the front, moving everything forward a bit is not all bad.

Lee

 

You're right about the possibility of damage. (or lack of)
I'm not worried about tearing the box off, but I think that running the steering shaft through the crossmember is a neat and tidy install.

Lee