Richard
"high misalignment rod ends will only miss align by 19% max"
You shouldn't need high misalignment rod ends just misalignment bushings, with both you could get even more angle.
"The front mount looks like 30 or so degrees out."
I don't know the dimensions of your arm. I was just drawing arms with dimensions from something I did earlier just as an example.
If your going to misalign the rear inner rod end then you might as well do the front inner by the same amount because it straightens your load path.
" Below is the version I plan on using unless someone does not agree."
If the outer rod end axis is not exactly transverse then when you set camber with it it's going to change caster at the same time, this necessitates correcting the caster with the inner rods ends which in turn affect camber. It isn't impossible but is problematic. That's why I angled the last arm drawing to show that the outer rod end was transverse. The advantage of your design is simpler construction and one less piece.
You still need to move the front leg connection at the outer rod end out until it's at the jam nut surface. It will give you more shock clearance and straighten the load path. Angling the front rod end as much as possible will do this also. Imagine 2 lines running from dead center of the outer rod end ball to the center of each inner rod end ball. This is the optimum straight load path. You want to get as close to that as possible with the clearance you have.
""Also I talked with my machinist/welder and he states that if you use self-annealing welding wire (which is not hard) you do not need to normalize after welding. This is what all chassis builders use when welding 4130. If you normalize a complete chassis you could end up with everything way out of whack since it also relieves any tension created during the welding process.""
I've argued back and forth and have been on both sides of the normalization issue. I've finally ended up thinking you need normalization to realize the benefits of 4130, without it you may be worse off than mild steel. Self annealing wire won't normalize the HAZ other than the deposited material.
Current technology has taken care of this issue, it's a machine called
www.meta-lax.com and it works without warpage. Maybe there's a welder close by that has it. Suspension arms aren't something you want to be brittle.