I'm in the process of doing just that, but with a 1 ton dually(BradB's 1 ton dually panel truck). I've got the crossmember narrowed and mounted to the frame. It's going through the paint stage now, then reassembly of the suspension pieces. When I cut the section out of the center, I cut it about a 1/4 in too wide. I then put a filler strip under the joint so the welded area was double thick and the quarter inch gap was filled with weld to insure the joints strength. In this application, the modern crossmember only needed an inch taken out so reassembly shouldn't be too tough,
Scott
P.S. OldSub, I've taken alot of pictures of the process, like you asked. I should have the front end reassembled and on the ground in a few weeks. If everything turns out, I'll burn the pictures to a CD and send you every picture I have of it.
