When constructing sleeved links with DOM (I.E. 1.125" O.D inside a 1.125" I.D. , etc.) is it stronger to plug weld them a few places in the center, or is it best to weld just the ends?

I've heard using heims for steering components is not DOT approved. Is this true? If so, any way around this? Someone told me that the heims can pop out of the socket, but it doesn't seem likely to me under normal abuse. I would think a 5/8" grade 8 bolt and heim would be stronger than a rod end.

Best to plug weld the bungs, cant hurt.
As far as D.O.T. goes. who cares? Ive been running heims on all my steering and link arm components on my daily driver for years and I think you'd be hard pressed to find a cop that says you cant run it that way. CHP has pulled me over, gawked at my suspension then sited me for mud flaps or some crap like that.

Yes, the ball can pop out of the housing but only if it takes a real hard shot from say,,,coming strait down on a rock :D I had this happen to a 1.25" heim on my buggy but never on my truck. My suggestion is, if you slam your tie rod or links real hard, inspect them but chances are, if the impact didnt pop it out, its not coming out.