Crush strength of material for sleeve.

I'm heavily considering using an outter sleeve on my delrin bushings, either press fit to the arm or welded in place, and i'm really struggling to decided on a material and thickness. I like the idea of aluminum, but the only things available are .065 or .250 wall and I'm concerned about the thin wall crushing and really don't want to have to use quarter wall. The next option is steel, and I'd like to just use general purpose mild steel so welding would be easy, but the options there are even more limited, almost exclusively to .187 wall.

Opinions?

the stock control arm "holes" are rolled, therefore not round at all. this means that a press fit of 'regular' tolerances will be sloppy.
I dealt with it by having a hard press with delrin, and hoping the plastic deformed enough to take up the slack.

welding in a steel sleeve would be a good option as well.

because of the non-roundness, i wouldnt use .065 aluminum, pressing it in can deform that out of round
.250" wall will be more than enough, but since it is only going to be contacting in some areas, it might move and get scratched up leading to slop over time.

I was planning on oversizing a big to take up some clearance issues, but it sounds like bumping to 2" even might not even cover it. Looks like opening up to 2" and welding in a steel sleeve will be the way to go, I've been talking to a couple people about doing some welding for me, so we'll have to see how that goes. I might box the underside of the arms at the same time.

i had to make each bushing hole-specific, since the tolerances were so far off.

That's just rediculous, once I get my spare set of arms, hopefully friday, I'll see what size I can\have to go to to make a set of sleeves to be welded in. I was just thinking, again, and while I'm having someone weld on the arms, I should re-do the swaybar mounts too. Should still be a hell of a lot cheaper than a set of tubular arms.