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Quick Q, air bagged or not? If so then the front bar will be a no go.
But the rest can be done not a problem.
As mentioned lots of tacks. Stagger the welds.
I would use 4mm plate. Most bigger companies (arb, iron man etc) only use 3mm but have a lot of shape which gives them the strength.
As for welding, 3mm fillets either side will be fine.. no point laying weld bigger than the parent material. Its just excess heat and can make the structure weak and brittle.
I would only be stitching the inside say 50mm miss 100. And fully weld the outside.
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