To start where you left off – perhaps one of the things to do is to familiarize yourself with the available data and as you said: re-examine the Beauchamps of Somerset. The 1841 census listings are the earliest, so you won’t find Susan before he marriage. However there is a small group of BEAUCHAMP listings for those that were born before 1800. Unfortunately, my limited access to the database does not show all the necessary information on locations that would allow these listings to be sorted into family groups or indicate places of birth. If Susan is born in Kilmersdon and married there in 1834, it is still more likely that her family is there seven years later. However if she doesn’t connect to one of the local families, then finding her as an immigrant is generally a more difficult proposition. So the question is a matter of which family lines can be established from the 1841 and 1851 census listings and what are their locations and their origins. Then do what you can to either verify or eliminate the more interesting of these possibilities.

While some apparently are willing to equate genealogical investigation and surname research, it seems to me that when you have to do it yourself, good genealogy depends on the discovery of the correct ancestral location and the existence of relevant documentation. It is at this latter stage that you can best use your knowledge of spelling variations. Can’t go after every BEACHAM. BEACHEM, BEACHIM and BEACHUM in the county. BEACHAMP and BOECHAMP also exist there in the 1841 census. We really don’t need another way to spell it, BEAUCHAMP works fine. Although sometimes it helps to try various versions of a name, since each search engine has its peculiarities. But ultimately good genealogy comes down to the discovery of relevant documentation. Thus a look in the LDS library, a place search in the library catalog, can turn up potential references. Under church records, the documentation of Kilmersdon begins very early, but I did not see all of these documents used as references in the IGIs. I can not find IGI references for Francis, Isaac, John, Reuben or Richard BEAUCHAMP, who are listed in the 1841 census. On the other hand, depending on your ease of access to the records office, you might just go straight to the source and see how that works. I am not a Somerset researcher and can not advise you very well with any specifics, but perhaps some of these general comments are useful.

Regards,
KA