Couple of random thoughts:
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Are you SURE the welds are unairworthy, or are you applying an incompatible standard of reference? ?Gas welds do not ¡°need¡± to be a stack of dimes to be structurally sound. ?Might suggest having another set of eyes on it before scrapping the fuselage. ?
Unless you are doing an absolutely optimized carbon structure, it¡¯s extremely unlikely that you are going to come in lighter than the steel tube and fabric. ?No way you are doing the Rutan style moldless composite lighter. ?No way. ?Burt used that method because it was easy to make complex shapes and iterate - not because it was light. ?
