seam welding and rear suspension strengthening, What to do, What I did... Options

[Andyrew]

So my project for a stronger chassis has begun.

Heres were Im at right now. Took the suspension out today.

I'll go do some welding and prep tonight, hit the bed, see what you guys say, and do some more welding tomorrow.

(IMG:http://www.teamgracer.com/cars/914club/914v8/914-8%20suspension-003.JPG)
Picture of some buckling of the suspension. Other side has a raised area, but is generally flat, this side has raised and concave area's. I'll be adding something here for strenthening, a tube? A flat piece of metal? A triangle?

(IMG:http://www.teamgracer.com/cars/914club/914v8/914-8%20suspension-004.JPG)

(IMG:http://www.teamgracer.com/cars/914club/914v8/914-8%20suspension-005.JPG)

(IMG:http://www.teamgracer.com/cars/914club/914v8/914-8%20suspension-006.JPG)

Here is some area's im going to weld, any two pieces joined together I will stitch weld.

[Jeroen]

andyrew,
the pic below shows 2 situations
in the top one, you will see that the shaft is slightly protruding beyond the shoulder of the bushing

the bottom one, the bushing sticks out farther that the shaft
this is not good

the shaft should mate to the suspension pickup on the chassis to prevent it from rotating (and loosening the bolt)

if this happens, you need to remove some material from the bushing so the shaft "sticks out" a bit

re: doorbar design
remember that the middle of the long is it's weekest point taking stress away from other parts of the chassis and focusing it to the middle of the long (as in your sketch) might not be a good idea