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my links are turned down to 1 5/8. My JJ's are 2" wide. This gave me just enough area to do a weld around. There is no fear of this being too thin of a wall, as the MOI needed for non-failure at the mounting end is much less than is needed in the middle. The link end is only concerned with sheer, and honestly, 1.75x.120 would be enough there. (i would never use something that thin, but just saying it would hold up fine.)
I don't like the idea of crushing the end of the tube, as that would create kinks that would be a spots asking for failure. Turning them down is a controlled process while crushing seems like it may produce random results.
How about clearancing just two side of the tube instead of turning the whole thing down...? That would leave your .500 wall on two edges and at least 3/8 or so on your weld edge... If i had thought about it, this is what i would have done. Not sure why i didnt think of it.
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