I'll post my method, just in case anyone else wants to try it!
Drill out the bolt head, this has to be done at an angle, so you need to guess/judge there the shank of the bolt is. The idea is to hit the centre of the bolt where it passes the slot in the cross member, being careful not to open up the slot!
Clamp it down...
cross member (2).jpg
Start drilling, judge the angle...
cross member (4).jpg
Enlarge the hole to about the bolt shank size...
cross member (5).jpg
Shear off the bolt head, fasten other side if necessary...
cross member (6).jpg
That was more accurate than I had hoped for!
cross member (8).jpg
(Other side of bush) I cut this from inside, with the Sawzall, it wouldn't fit the other side of the bush.
cross member (3).jpg
Now to remove the bush. With fire. Lots of fire.
cross member (1).jpg
I noticed the exhaust was very close to the crossmember, so thought I'd put some air around it....
Before:
After:
Nice, very neat.
I like your problem solving approach, that kind of thing goes down well round here. To many people give up way too easy.
:)
Template of the cut out's might be a good thing, in case anyone local is lucky enough to find a pot of gold
Don't worry Alan, I can easily make a template with it fitted to the car. However, I'll photo it with the tape measure in shot.
A coating of Kurust on the welded seams
Then seam sealer.
Then blowtorch to heat the crossmember, and boiling water to melt the underseal. Fill the cross member with 700ml, swill it around, and let it dry.
The inside should be weather proof, the outside will follow.
Loving your work. :)