What you are replacing it with is much thicker metal and tougher then what you are removing. I spent a lot of time trying to save as much of the cross member as I could when installing a CC skinny rear bumper. In the end there was so little of it left, I ended up removing it all. I pull a M1101 trailer with it without a problem.
Structurally I'm sure it's fine, but as I stated, if you get in an accident and an adjuster sees a hacked up frame, you are screwed. If it is a trail only rig, I wouldn't have a problem doing it.
Yeah, I have reservations, and won't do it. When I get rear ended and the insurance adjuster look under there, I don't want him to see a mangled frame. Nope. Not doing it.
I'm sure you are right but after cutting, grinding, and reprinting I would wager that 99% of insurance adjusters would never know it was there in the first place. I can't comment on other's but mine definatly does not look hacked at all. Things may be a little different where you are, but in my neck of the woods you would be hard pressed to even find a adjuster that would be willing to crawl under a vehicle.