Hello Airhead, welcome to the forum. If the gaps are as you say they are OK, a small gap when welding is not a bad thing so long as you don`t let it get out of hand and sloppy etc.You need to keep the overall measurements of the chassis really accurate though, if the plans say the chassis should be a certain length or height at a certain point then concentrate on that more than the gaps. When you come to fit the suspension brackets etc you will be really pleased you did, it makes life MUCH easier!
Dennis.
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