you will be welding a structual spot- if you dont know how to weld get help. What will you be using, mig or stick?
You need to cut back as far as you have to until you hit solid metal. Bevel your cuts. Your root pass needs to be the strongest.
If you feel better about it, put a gusset plate over the joint you weld.
Just remember, everytime the suspension moves you will be changing the load that weld sees- so it needs to be strong. The stock frame rail is 1/8", so you can use that in your replacement material.
I will be using MIG. I didnt like the idea of stick welding suck an important area...but admittedly, I dont know how to weld. I also was thinking Id add an extra plate for reinforcement, it just made sense.
I'm pretty darn quick to catch on to things, and I have a neighbor who welds for a living. Heck, he might be willing to come over with his welder and zap it for me.
I planned on doing it myself though, after some reading and practice. If I can get help, all the better. I was going to buy a good but not overly expensive welder for the job, which would allow me to do a lot more bodywork-wise and also do my own exhaust work. I suppose if he will do it, Id save a few hundred bucks. Just a lil something for the basic hobbyist/farm equipment repair/auto body.
Ive got solid metal with just surface rust just before it curves, which I thought might make it easier overall to get leveled and attached perfectly. I was actually hoping to get a scrapyard to cut out a rear section of frame from a wrecked one, so I wouldnt have to fab the leaf spring mounting bracket. The less involved I have to get, the better with my inexperience. I prefer to learn one step at a time, not dive in headfirst and wind up ruining things.
I know what a good weld looks like; just not how to do it. Im a construction inspector during the day, and have some light experience checking welds...but none at all in actually doing the work :P