What I was thinking.
Is it actually stripped and string-lined now, so you can see the full extent of the damage?
We rebuilt a 6.5ton Iveco last year, it'd had a minor roll. We stripped the body and subframe off it (tilt and slide recovery vehicle), but it wasn't until the cab came off it that the bow in the front part of the chassis was evident.
By this time there'd been a lot of work done, so forward seemed the only way to go.
After the cost of having the chassis jigged, the man-hours involved in straightening the cab, replacing the steelwork on one corner of the bed, rebuilding the suspension, it wasn't a cost effective excersize.
Had we have known the full extent of the damage in the first place, we wouldn't have rebuilt it.
Our fault was, we only looked the chassis by eye, from underneath. We should have string-lined it properly to check the dimensions.
Bear in mind that as you weld the outer part of the chassis, you'll burn the galv on the inside. It will need waxoyling inside once done. A chemical dip won't take the original galv off properly, the only way to do this is to have it blasted (with a proper blaster, not one of those machine mart bucket jobs). Even then, the new galv won't take to the old galv on the inside of the chassis very well.
Sure the job's worth less that the price of a new galvy chassis?