I would think the #7 was a much easier project than the two sides of the #9 cylinders. Cast iron welds fine provided its a good quality. Some times you run into iron that does not like to weld well. The fact that this one cracked makes it possible its a little brittle and it may not take the weld well. We have repaired cast iron castings in the 15,000# range so its certainly possible. You really need a lot of preheat that stays constant and its quite unpleasant to weld on with all that heat. There is also the possibility of further cracks once the welding starts. If she is not abused they can run her for demonstrations sake. She would need a new boiler for the loop as this one will need major work for the FRA and at its age I don't think its worth it.
This is a problem with this valve gear and frame arrangement. There is not really room for substantial frame spreaders and the cylinders become the only structural support for the majority of the frame, With spreaders at each wheel station the frame acts like a I-beam.
Have a great 4th everybody. And please stop calling me Mr. Braun. I'm only 61.
John Braun