good tips, thanks beau...

im not completely clear on what you mean by #3...do you mean to use two sheets?? one with a basic frame and one with a complete sheet???

and secondly, dont the torsion bars articulate??? i was under the impression they did, but i could be mistaken (similar to the control arms)...
if not then i would definately cover them....

these are very very rough still, i would use kenny's design initially and then just make a few tweaks...