Here's the process of making the header panel. I used 18g and made it in three sections since it wouldn't fit in our bead roller in one piece. Making it in three pieces also allowed me to work out any distortion around the rolled bead in the shrinker/stretcher.
The bottom part of the original header was completely rusted off and stayed with the lower cross brace, that's why its much shorter than the new pieces.
Laid out the stamping pattern for rolling using 1/4" offset dies.
First of three panels rolled. I only rolled the depth of the bead 1/8" to minimize warping. The bead roller has a 20 gauge limit so I also didn't want to push the roller to do something it wasn't designed to do.
Aligned for welding.
