The strength of a beam lies mainly in the web height. Then some in the thickness, with a smaller amount in the flanges. I've seen 18 inch tall I beams (used on a commercial roof) that spanned 40 feet yet only had a 5/16 - 3/8 thick flange. Given the flanges are OK, I'd say an additional 3/16 should be plenty, as you're simply reinforcing what's there. Even with some corrosion that the additional material will make alot of difference.
You say you're doing it in pieces. Unless you're doing that to go between cross members, or other obstructions, you don't want the pieces to tie together with the ends vertical to the frame. The frame rails will flex under a load,and a square cut end won't be that strong because the pieces will want to pull apart as it flexes.
Instead, cut each one at an angle, so the ends of the pieces overlap. This gives a longer, and stronger, connection between the pieces.
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Today's Featured Article - Grain Threshing in the Early 40's - by Jerry D. Coleman. How many of you can sit there and say that you have plowed with a mule? Well I would say not many, but maybe a few. This story is about the day my Grandfather Brown (true name) decided along with my parents to purchase a new Ford tractor. It wasn't really new except to us. The year was about 1967 and my father found a good used Ford 601 tractor to use on the farm instead of "Bob", our old mule. Now my grandfather had had this mule since the mid 40's and he was getting some age on him. S
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