- sha1(var1 + sha1(var2))
- sha1(var1 + var2)
Neither is very secure. Don't reinvent the wheel. HMAC was designed for this; in particular, it takes steps (padding, etc) to avoid issues with certain weaknesses in certain hash algorithms interacting badly with the above 'simple' implementations.
Additionally, double hashing isn't useful to improve security. Consider: at best, you'll map from one random-ish value to another random-ish value. However, if there is a collision two resulting values from the second hash are equal, you've lost security by ending up with a collision. That is, you can never get rid of a collision this way, but you can gain one.
That said, existing preimage attacks might not work against double hashing ... but! They might still work. I'm not qualified to say which, and if you're asking this here, you're probably not either. Certainly collision attacks, which are all that are practical with MD5 today, aren't hindered by double hashing.
It's best to stick with the proven algorithms that have stood up to decades of analysis, because with cryptography, it's all too easy to make something that looks secure but isn't.