What gauge is the frame rail? Im chopping the old rusted piece out. This is the small piece between k member and bumper.

Next question, does the car have to be leveled perfectly like it does when welding in subframes?

 

Not sure on the gauge but I've seen heated discussions about welding subframes. Some say it needs to be on its wheels under load (IE ramps), others say no load on the suspension is needed. Good luck.

 

Right, thats why i'm wondering if this small part of the frame rail would need the same...um... meticulous preparation.

 

Mike, My recommendation to this would be to take equal measurements from the firewall where the frame rail is. You can also draw and outline of the old peice. Take a bubble level, and see how far of an adjustment it is on the rail to the front bumper. Throughout the entire process, keep in mind all the distances from the shock tower to the top of the frame rail, the battery tray area to the frame rail and so on. Tack weld on a few spots, measure, and measure again. Hope this helps.