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I would hammer it flat, get a dremel in there and put a nice bevel on it, if you have to pound flat again, then weld it shut, then put a plate on it. Only if it is not affecting the geometry on front end, if it affecting front end,straightened the problem area then weld and reinforce
After you weld that up you want to add a gusset from the hanger to the frame rail.http://www.google.com/imgres?imgurl=http://i119.photobucket.com/albums/o159/ocdropzone/frame/hanger_gussets1.jpg&imgrefurl=http://www.pirate4x4.com/forum/toyota-truck-4runner/1956610-latest-my-88-a.html&h=400&w=600&tbnid=WDmMYzQgOzraQM:&zoom=1&docid=trvAa62ShZJf0M&ei=ROo-Vf6eIMWpogSRkYD4AQ&tbm=isch&ved=0CEEQMygaMBo if this link works it shows what Im talking about. Not my work just a random photo. Also the ends of your hanger are hanging out there unsupported. I would weld a piece from the new hanger, to the old hanger, to the edge of the body mount bracket. Hope that makes sense.
Wow, I haven't seen cracking in that area like that. Im curious what the cause is. My frame has some cracking in the more typical area of the front frame.
I havent seen breaks in that area before either. My runner broke on the sides of the frame between the steering box and the hanger.Do you have a winch by any chance?
I just wondered if winching had caused that. When my frame broke i plated the outsides up to the very front, i welded square tubing under the frame and welded it to the backside of the hanger. I still had cracks at the steering box, could see it on the inside of the frame.
Here's what a shop did on mine as part of a cracked frame repair. I still need to mirror it on the passenger side and add frame reinforcement plates to the outside of the frame rails.
http://board.marlincrawler.com/index.php?topic=91592.msg1030842#msg1030842
So i didn't do the SAS on this truck and i'm not sure what's the PO did here to install the spring hanger kit. after a couple wheeling trips, it looks liek the OE frame cross member is starting to crack.
I bet if you look more you'll see more cracks in the frame. I brace mine all the way from the body mount under the door to the very front taking out the front body mount I'll try to get some pics, I've went as far as the whole front bracing too plus inside the frame to the motor mount.
Wow. That's some crazy damage.
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