I can't tell if it would be easier/better to replace or repair/patch this Model A cross member. Thoughts?
I would cut it back so you had a nice square hole and then put a plug in and weld it then make 2 smaller triangle pieces to fill the triangle shaped holes that will be left after the square piece is put in. weld them and grind and sand smooth if you really want to be **** about it and hit the whole area witha needle gun to blend the metal texture. If you are in a hurry or don't have the welding skills and you have a fat wallet buy a new one.
Replace it and give it to me What do you think I will do to it? I had a Harley springer for sale at a swapmeet It had the common split seam A guy wanted it til he saw the split. I suggested he weld it. Naw, he didnt think that was good enough... I took it home, welded it At the same swap meet the next year he bought it
This may sound like a really stupid question, but where can I get s**** metal in that small of a quan***y. What gauge should I use.
Just for structural integrity cut a rectangular hole with radiused corners (rounded) and make your replacement piece with the same rounded corners. Bevel both pieces leaving a small "land" area intact. That way you'll reduce stress points from the welding. This will be a high stress area of your frame.