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I would pick the welder that chose the the 5" tube for the frame. I would not recommend that the outriggers be made of sheet metal as they are what really hold the shell to the frame. use the 5" tube for these as well except that you should be able to cut the profiles on the outboard sides to match existing. You will have a frame better then the lighter duty original when done
Your method of removing the shell sounds good to me. Remember that there's no totally right way to do it just as long as you get it off then on again without damage
Any good sheet metal shop should be able to match the wheel wells with galvanized.
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