[Treeve]

So, move the tubes and redesign the connection. Making everything thicker and heavier is a cop-out. Putting the a-arm together then drilling for the suspension mount tube through the side will reduce this, and then reinforcing plates can be added. Alternatively , running some numbers on appropriately sized gussets and designs can help to ensure there is no significant change in modulus through the arm and hence eliminate the sudden change. Finally, you could go back to scratch and consider changing the top mount so you can move the bottom mount. This then changes the force paths and hence you could redesign it to be stronger and lighter.

Treeve ‘not my first rodeo’ the engineer