hey brent.
If you recall I welded (ok crash welded!) a 2" x 1/4" strap along the bottom. This was about 10" long and covered that tear in the frame. I had to drill holes in it to give me acces to the sway bar bushing/mount. I also bent it to follow the bottom contour of the frame rail.
When I got home I got some 1/4" plate and welded it to both sides of the unibody rail and butt welded my tomken bumper mount to it so that my bumper had more surface area to mount to. These side pieces ended up being about 10-12" x 4" and I had to cut the contour of the frame rail into them (they ended up like a parallelogram if you follow me). I stichwelded these on about every other inch.
I also had to lay the steering box spacer on them to drill holes thru both, and ran longer grade 8 bolts thru the steel, the frame and into the steering box. Steering is rock solid and no more creaking noises.
how are things? You working yet? I see you have another XJ project underway.
SeanP