Bill:
The specification for the frame reconstruction it would seem to me needs to address the C&TS requirement? that cars that will be used in revenue service have metal reinforced frames. Since I am assuming you are considering another caboose or passenger car as the next Friends project this needs to be addressed.
Assuming then that the frame must be reinforced with steel I would think that it would be more straightforward to bite the bullet and construct a welded frame from tubular steel. Yes, I know not historically accurate etc. etc. but I also think given the liability of a derailment that it would be wise to listen to Earl Knoob, John Bush and others who understand the tourist side of running the RR. Restoring equipment for static or limitied use vs. the dynamic stress that the C&TS will impart on equipment is where I think the project should focus. After experiencing your handiwork with 0579 this past week I think you would agree that restoration for revenue operation (when possible) should be the goal. In closing I think this frame design critieria is important enough that it needs to elevated to the Commission so that all parties of the Triad agreement (Commission/ Operator And Friends)are on the same page as to what the restoration game plan will be and how this dove tails with the RR operating plans for the coming years.
Rod