Yes, the van stayed in my driveway. However I worked on the parts in my garage whenever possible because it was getting cold here. My flux core welder did very well in windy condition.

 

Here are some pictures.

This is the driver side horn after I removed the front crossmember beam :

https://picasaweb.google.com/1011130...18683500757506

Whatever is left from the front crossmember beam :

https://picasaweb.google.com/1011130...18692093277538

The driver side horn after cutting the rusted part :

https://picasaweb.google.com/1011130...18676806986050

Test fitting the horn and crossmember assembly with tack welds :

https://picasaweb.google.com/1011130...22551577836882

Crossmember coated with tar-based underbody protection :

https://picasaweb.google.com/1011130...22552007183442

 

Looks like a great job to me. Where did you find the 1/8 steel to do that?

 

I started looking at Home Depot and the others but they only carry thin 1/32 inch metal sheet for body work. I had to go to a local professional metal shop which also sells to the general public in small quantities. The same guy agreed to cut and bend my parts.

I am happy with the end result and I am sure that it is stronger than the vans that have a lot of corrosion in the frame.