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71 suburban rust repair help
Looks like this is a common problem.Mine had pin hole porosity all along the top.I removed the cross member and had sections cut out and re fabricated. Where the cross member attach's to the body was also bad. You might try for a used cross member. There are about 30 spot welds to drill.When I did mine I had the floor out which allowed me to clamp the cross member tight to the vertical floor section when re installing . It was a big job. In retrospect I wonder if it would have been easier to fab a new cross member using a plasma cutter and steel U channel of some type. The problem is the bend at each end.You will need to find a good sheet metal guy with a strong sheet metal break. I found a magician who did mine for $250 but complained about how long it took. I was glad to pay anything! It was a solid repair!
If there is enough solid cross member remaining it is possible to repair it. I did repair mine and also the rear tail pan cross member. I will post some pictures. Hope this helps
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