I know nothing about metal working/welding, so no judgment from me on the welds. They are beautiful in my eyes.
Well I wish I saw what you saw. haha I've thought about grinding them and redoing them but it doesn't bother me that much.
Your BMC was one of the first I came across when searching. And you are right...all others seem to have just cut off the body mount at a 90 deg angle and capped it off. I like your logic for the purpose and it seems like your method would retain some of the strength and that original purpose...but it doesn't seem like welding a steel plate on the others would really add any additional strength? Plus once they are cut off, they certainly don't offer any protection in a collision.
The only thing I see is the end cap will prevent the open ends from being able to bend backwards. With the cap on it, it may solve that issue. Again this is assuming my reasoning for the BMs is correct.
Unless the overhanging portion of the body mounts are an overall structural support for the vehicle, I would think skipping the welding aspect wouldn't change anything other than the look. I know how to search this forum and others....and have read through all the BMC write-ups. I know what needs to be done and "how to do it"...just looking for a reason I guess. Similar to your reasoning, I am just looking for an inexpensive (free) alternative to UCAs. What can I say....I am cheap!
The force on the mounts from the body are from the actual mounting position and inward. There should be no force acting on the outer edges of the body mount. Harper7 just cut his out without welding it shut. If you decide to do that, make sure you round off the corners so you don't tear a hole in the tire in any situation where the tire might make contact with the BM.
I haven't even felt any rubbing on the body mount, but there are obvious marks on the mounts and based on the pic I posted in the Level 8 MK6 thread...the wheel def touches at full lock. I can only imagine that the effect will be magnified in any offroad situation. I just don't think it has enough effect on my day-to-day driving to warrant $400+ UCAs + cost of alignment. That's a lot of money I can put elsewhere....
If you're making some serious contact with the BMs, you'll know it. I can assure you of it. It may rub some hear and there. I don't think I would have even rubbed if I would have taken off my wheel spacers. I don't blame you on the not wanting to spend money on UCAs right now. I'm the exact same way.