Originally Posted by ant_8u
Also, I've ground the bonnet hinge box off of the front crossmember so it can go on again correctly, but it's burnt through in a couple of places
Is this still good, or should I buy a new one?
They're pretty cheap, so I'll buy a new one if that's best, but I'd also like to keep all the original items where possible
I would use that piece to practice weld on and get a full thickness piece to install.
Your grinding looks like it has reduced the thickness of the material quite a bit.
When grinding you need to be aware of the thickness and try to maintain it or the strength is diminished.