I'm moving along pretty well with my own control arms. Due to some unfortunate circumstances, I had to go with a more expensive, more time consuming but ultimately stronger control arm.
I basically have 2 designs on the table... one which I'd call a "drag" that's meant to be light weight, but not neccessarily the strongest arm, and the other which is meant to be used hard. The first requires harder to find tooling (haven't had the opportunity to look for it yet as I've been focusing on the second design more) and the second design requires a bit more overall work.
For now, I've taken apart my rear suspension, and on both sides, I had the front lateral link outer (knuckle) bushing sleeve rust itself onto the bolt, causing me to shred the rubber bushing to bits while loosening the bolt to remove it. Obviously, if the bushing cannot spin freely on the bolt, there's going to be some binding going on. Also though the rubber in the bushing is fairly low profile, it's still fairly soft and has noticeable give.
Here's a pic of what I'm talking about:
I'll post up some more details and pics in the next few days... with any luck, I'll have the "second" design put together