So i am sitting here, waiting for the time and money to get a set of Steve's SFC's, and i notice the crappy fit and scarce spotwelds that hold out cars together. The idea started when i was repairing my chassis after it cracked at the steering box. the sandwich of metal that makes up the inner wheel well ( 3 layers ) totally delaminated and was a swingin in the wind. I drilled some holes to re spot weld it and ran a bead over the ends of the sheetmetal. As i look at pics of the underside of my car i noticed that the frame rails overlap in some places and don't even touch accept where they meet the floorboards, and there are other sections that come together really sloppily. Has any one tried to weld these areas with continuous beads? What are your opinions on stength increases? Any similar ideas?

 

Yes.

It definitely makes a difference. Go ahead and do it, you can't hurt anything as long as you only weld stuff together that's supposed to be welded, and like you say, there's lots of room for improvement.

Not just underneath the car, either; the same thing exists all over the body.