92 accord was curbed. I changed bent front sub frame cross member behind the radiator that the radius rods attach to. It has 2 bolts w/ washers on each side.
Driver side bolt hole in chassis above sub frame cross member is elongated now. When the cross member was pushed back the bolt elongated hole to the rear in chassis frame 3/16. The threads seem fine. I was able to force the bolt back to original position. The threads ( nut) in chassis frame rail seem fine. The threads ( nut) inside chassis frame rail seem to be welded to a plate.
I am concerned that if I don't weld a washer or another piece of metal, over the elongated hole in chassis frame the bolt when installed could push sub frame cross member towards the back if I hit a bump. The added washer or metal would lower the sub frame cross member down 1/16 to 3/32. I don't think this will effect my caster or camber. The sub frame front cross member behind the radiator would be against washers or extra metal welded to the chassis frame fixing the elongated holes.
Will this work or any advice, concerns, opinions, etc. Thanks in advance.

 

From the description I do not see why you would have to do anything other than install the 'new' front beam, verify it is squared up, and torque down the bolts.
Hitting a bump will not cause the front beam to shift, a collision where the wheel or lower front suspension is caught may cause such problem, such as you have previously experienced.

Bolted to the bottom of radiator support the bolts are not the only item keeping the crossmember located. Bolts do provide the clamp load, but to move the crossmember would need extreme force to overcome the surface friction of the crossmember to the chassis. The hole you are concerned with is just a window for the bolt to pass through to the chassis nut. As long as this window does not affect how the front beam is mounted I would not concern yourself with how it is distorted.

Pictures would be helpful, but I believe what you are concerned about will have no affect on the car. Unless the collision was enough to cause the radiator support to also be distorted and pulled back, but this would be noted when the wheel goes back on and it is still too far rearward.

 

Thank you for your reply Mad Mike. I will put it back together.