#1.What gauge of welding stick works best? (The welder I plan on buying uses 3/32 sticks best)

#2. looking for suggestions on a roll cage/Cab brace mounted behind the front seats. I removed the back seat for good.

#3. Anyone done an exo-skeleton on the SWB gen1? If so please share details.

#4.Possibly considering doing some serious truck surgery.
The rear most cross member tube is getting pretty ate up with rust. In addition to that my fuel cell while not leaking does have a corner crunched in a bit. Rust will prolly come for it next.

I'm considering removing the bumper, and digging down to the rear cross member tube, cutting it out with my angle grinder, grinding down what's left of it and welding in a new cross-member.
Since I'd need to remove the fuel cell to do this I'd also be throwing that out and making either a rectangle or square fuel box to replace the old tank with.

Thoughts on this?

I should also point out that I am doing my damndest along the way to rust proof as much as I can. I am grinding and brushing off the spots of rust and using KEM BOND HS industrial primer as the first three coats and another three coats of Industrial enamel HS. I plan on covering as much of the inside and outside of the body and painting the frame rails from bow to stern.
If you guys are interested you should check out the MSDS fact sheet on this stuff.

1) Depends what you're welding.

2) Need a full cage if doing #3

3) There was one on Pirate. You need to do a cage inside before you do one on the outside.

4) Use that as an excuse to bring you fuel tank up.

#1) I'd be welding on the inside of the cab and outside, in order to build the exo and rollcage.
Also replacing the rear most cross member.

#2. Thanx mud raider

#3. Searched a bit across multiple terms and couldn't find the thread on pirate.

#4. I'm guessing you agree with handling the fuel cell and crossmember tube together. Anything else to add?

Thanx for the reply mudraider.

#4 yes

Here you go

http://www.pirate4x4.com/forum/showthread.php?t=1033273

That Link redirects to some infuriating ad service called "Skimlinks"

Well, look for the thread titled, "my 88 pajero, what's left of it. "