[DransportGarage]

I've been pretty busy working on body prep for paint but I did get around to fixing this problem this morning.

When I looked into the frame I realized that the weld I had put in to close the hole had left a really bumpy welded surface. Gluing a nut inside the frame was out of the question, so I rounded and beveled some 1/2"-13 nuts to a little less than 7/8" O.D. (Pic 1). Then I cut a 3/4" hole, enlarged it with a carbide bit for plug fit and beveled it. I welded in the nut, used a double layer of tape as a grinding guide, ground it off, brush-primered and painted it, mostly for corrosion control (Pics 2-5).

I dabbed the repair with a wet rag between every weld to minimize damage to the paint. I could have fully filled the bevel, but that would have risked bubbling the paint. It's plenty strong. The repaired area will easily be covered by the bracket.