On one side, the internal threads were gone and the bumper bracket was welded on and on the other side, the threads were rusted out. Here is how I fixed the mounts.
First measure from existing mount holes to another point on the frame for later reference. Mark a vertical line a little past the mounting holes and cut just the outer metal of the frame rail. Mine was not terribly rusted out so I cut only about 8 inches back just for replacing the threaded holes.
Next drill out the spot welds around the front edges of the rail. I actually ended up cutting a couple of the bottom ones with a disc. Remove the old piece.
Clean up the rust and prime.
Measure, mark, cut the new front out frame rail piece to fit the space. On mine I drilled holes for plug welds. Verify that the hole measurements are what they were before and clamp and weld in place.
Since I had a lot of metal left after cutting the rail patch to fit, I used the rest to make the patch for the other side. I took measurements and drilled holes to match the old metal. I welded in a couple nuts and cut it to match the old piece. I also needed to add the tabbed piece on the end that the lower valance and bumper guards bolt to.
For the buckets and headlight doors, I just used some of the spot putty for scratches and pits. I sanded smooth and repeated the high-fill and a couple touches of spot fill followed by some wet sanding with finer paper and another coat of high-fill and more wet sanding.
I needed a good top coat for the rough hot rod phase. It'l be a while before real paint goes on and I plan to drive it ;)
I experimented a little and came up with a buffed primer finish that looks a little like the dull black paint that some people like these days. Its just a black wash-primer lightly buffed after it dried.
All assembled with its new grille, its starting to look road-ready.
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