My new Festiva

[purg3d]

Thanks, bravekozak. If this doesn't work, I may look into sourcing a new frame rail. I came up with another design for the patch. Camera died before I could get a shot of the underside, but it basically runs into the corner along the rail.

Patch will be welded all around if we can do it. Should the patch extend into the sway bar mount?

[purg3d]

If any of my east coast brethren think they can do the repair and make the support bar, let's talk. Don't think we'll be trying this any time soon.

[Advancedynamix]

I would drill holes for a spot weld seam using a mig welder. This reduces the strain along the HAZ area of the welds. The heat affected zone (HAZ) will be more susceptible to cracking than the base material itself.

[purg3d]

A friend of the family was willing to take on the project. He didn't know about the frame rail, but I think he did a great job reinforcing the radiator support.