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More strange stuff with my project.

I had my Running Boards blasted and look what we found PICTURE

That appears to be metal fatigue cracking, but at the end of a running board? Isn't that kind of cracking the result of vibration or continous flexing? It's no big deal to repair but I just find it unusual to see this on the end of a running board.

Any thoughts on this?

Had something like that on the back end of one of my running boards. It was more around the support bracket though, so I was able to weld a patch panel in. Your board looks to be in good shape besides that cracking. I had to do a lot of cutting, welding and grinding on the edges that contacts the fenders because they were rotted out.

Have a look HERE and I think you'll get a better idea of what I'm facing. I'm going to need at least three patch pieces as well as all the brackets and stiffeners for both boards. I came real close to scrapping them but with the availability of the patch panels and the astronomical price of new or used I'm going to restore mine.

I've got a LOT more time than money.

Wow, after looking at your pics, I'd personally get new ones. But I can understand about having more time than money. I butt-welded small patch panels in my running boards and they look pretty good. I messed up- welded too fast and the boards twisted a little, but I think they'll be fine when I bolt them down to the brackets. I had to use a small amount of filler (all metal) to fill in some deep pits, grinder marks, etc. The other day I put 3 heavy coats of K38 on them to fill in small pits, imperfections, etc. All I have to do is sand that down and paint them with the ceramic chassis paint I just got from eastwood.

I would braze those with bronze rod from underneath, a good thick coat of bronze will reinforce the area from the underside.
Also it is easy to shape on top. You have to be able to run brass though.

I plan on TIG welding the patches in. You can see the rust-though where the bracket used to be welded so most of the ribbing will have to be replaced. The end where the mounting holes are will have to be fabricated and cracks welded.

The damages is too extensive for brazing but your reasoning is very good. I have to get some brazing rod.

I'm guessing that since the fenders bolt to both the running boards and the bed that your bed mounts are shot, and the running boards are trying to support the bed sides through the fenders.

That's quite possible considering the condition of everything else.