My trans/t-case crossmember is bolted up. :D I'll snap a pic next chance I get. I used a TJ AX-15 mount, but I imagine there's a way to get the same result with other mounts. :dunno: For the custom crossmembers, I just looked up steel shops in the phone book and found one that both sold steel and would do some simple fab work. They cut the steel to my specs and then folded up the sides at a 90*. Nice and simple and reasonably cheap. :D
As to welding, I own a $65 stick welder that's running through a 15 amp circuit. It'll blow the breaker if I go longer than 5 seconds at a time. :( And it's not powerful enough to truly weld either. But these limitations didn't stop me from getting the job done. I use what I call the "bubble gum method". I stick the weld material to one piece, then the other, and I make a small bridge between them. Make enough of these bridges and the part is strong enough to be removed and taken to a pro.:D I would never trust my welding skills with my life, even if I had a 220v welder. I found a local welding shop in the phone book and he did the welding on my bumpers and suspension crossmember. The majority of the rest of the welding on my truck was done by a semi-local semi-pro that does fab work on the side for fun. Since he's not insured, I did a thorough job of talking with previous customers and checking out his handywork for myself. He did the rollbar and rocker guards.
Ask around and don't hesitate to use the ol' phone book (or yellowpages.com). :cheers: