[dsraven]

if you remove the cross member maybe throw a length of angle or tubing of some sort across the rails behind the bumper mounts before you cut it out. that way the rad support will have something to keep the dimension correct other than the front bumper. maybe less vibration on the bumper when driving as well. just a thought.
when you boxed the frame what method did you go with? cut the box plate thanks same height as the frame and grind an angle on the edges for the weld to penetrate into, then grind the weld down smooth to match the frame height? cut the boxing plates slightly smaller in height than the frame so the weld made up the difference in height? space the boxing plate off the frame the thickness of the plate and then weld into the cavity so the plate is actually a little wider than the frame in that spot? curious because I did full length boxing plates on a task force and opted for the "cut the plate the height of the inside of the original frame" and then ground the welds down after. that left a good space for the weld to sit even after grinding the area smooth.