Re: Working Man's Burbon
 

Thanks Doc! I can't wait either.

Re: Working Man's Burbon
 

"If it was easy to drive a old vehicle then everyone would be doing it!"
I've been saying that for years and living it all this month.
Once the driveline was installed I checked the U-joint angles. The one piece set up definitely changed the angles. The transmission angle didn't change, but the number I read did since I did the readings up on the jack stands this time.
The new number for the transmission is 2 degrees down.
The drive shaft was at zero degrees.
The pinon angle was at zero also.
Not the best arrangement. So I ordered a pair of 2 degree shims (Last photo) from Speedway Motors as there was nothing available locally.

https://www.speedwaymotors.com/Rear-...SABEgIe6PD_BwE

A couple days later I had them installed and once I had reset the bags to ride height and had double checked that the transmission number hadn't changed I checked the other angles.
Transmission angle 2 degrees down
Driveshaft angle 5 degrees up.
Pinion angle 2 degrees up.
I was surprised that the drive shaft angle changed so much with only 2 degrees of pinion change.
All this means the U-joint angles are now both 3 degrees. Just about perfect in my book. And all this leads to the "It's not easy" part of the project.
When I was originally installing the drive line during the GV installation I had noticed the yoke was damaged. One of the centering tabs for the U-joint bearing caps is shaved off. (Photos 1 & 2). Photo 3 shows the undamaged side. I used a C-clamp to install the U-joint caps. I put one end on the yoke and the a socket on the opposite cap and slowly closed the clamp until I felt the cap on the damaged side was where it should be. Then I torqued the cap bolts. Not the perfect solution but I felt it was good enough to drive for a short time and see how the drive line worked.
I drove it to across town and picked up a pair of free RUSTY Pontiac blocks. The truck now drives super smooth. Better than it has ever been for me. Next step was to go by the rear end shop and see about getting the yoke replaced. They ran out and measured the yoke and got me a new one (Photo 4) and explained how to install it with a pneumatic impact wrench. I was leery that it would work. We talked about for several minutes and went over it a couple of times. The idea is to push the yoke on and put some loctite on the threads then rattle the nut down and stop the moment the nut quits turning when it contacts the yoke. It is supposed to not change the crush of the sleeve that way. Well I should have listened to my inner discomfort about the procedure. I was worried my hot rodded impact would be too quick to stop in time so I turned it down a notch and turned the air down to 90 psi.
Needless to say I didn't get it right and after I had it buttoned up I backed it down the alley 30 feet and the rear end began squalling. Damm!
So this morning out the door at 7:15 and at 8:45 rear end was in the back of the Blazer and off to the shop.

Re: Working Man's Burbon
 

Yep that's a bummer, and also why I decided on my truck to tear everything down 100% and replace anything suspect with new parts. I really want to be able to drive my truck without worrying about issues cropping up mid-drive like my other classic car.

Re: Working Man's Burbon
 

I think when it comes time to rebuild my junk in a few years, I'm going to go CV joints and a carbon driveshaft from The Driveshaft Shop....super spendy, but all the pro touring guys swear by them and with the CV joints, you dont have to worry about pinion angle.

Re: Working Man's Burbon
 

I thought that's what I had done with the rear end 2 years ago. I had it gone through from end to to end. One new axle new ring and pinion, all new bearings, but they apparently missed the bad spot on the yoke when they bolted it all back together.
As I said "If it was easy..."

Re: Working Man's Burbon
 

My only encounters with CV joints has been with a 74 Dodge power wagon 440 w200. That truck would eat the CV joint every 20-30 k miles. Ended up replacing it with a regular drive shaft with U-joints. It didn't last any longer but it was only $30 to fix instead of $175.
The drive angles aren't hard to measure and usually they aren't too tough to bring in to line, unless you have veered way off the factory playbook.

Re: Working Man's Burbon
 

Fair enough...I also suspect it largely depends on how much power you're putting down, and the weight of the vehicle you're moving. All the guys having success with CV joints are running big horse power in highly modified cars (hence the angle issue), but all are well under 4K lbs....so gross weight may play a role in that.

When I eventually convert my truck to 4wd, I may run a divorced NP205 transfer case with a single piece CV driveshaft going both forward and aft....a lot of that plan is TBD however.

Re: Working Man's Burbon
 

By the way, I used a solid crush sleeve replacement with shims when I did my rear axle, in part so that I wouldn't have to take it apart when I inevitably went to far with the preload. So I have a few crush sleeves here that I didn't use and I'm happy to send them to you if you want to try replacing it yourself!

Re: Working Man's Burbon
 

Thank you for the offer. I delivered the rear end to the shop last Friday and hope to have it back any day now.

Re: Working Man's Burbon
 

That Dodge was the exact opposite of a pro touring car. With 150 gallon diesel fuel tank, oxy-cetylene torch set, service boxes full of tools and stuff, 4 or 5 chainsaws, and 3 or 4 grumpy loggers on their 30 to 50 mile drive up into the woods. I'm sure we were running at or above the GVW. We also converted from the full time four wheel drive to locking wheel hubs to keep the transfer case the alive.
The frustrating part was the 70 K20 with the 292 the Dodge replaced never gave us any problems.

Re: Working Man's Burbon
 

The seat project has not progressed as nicely as I would have liked. I reinstalled the foam and put a cover on the back and bolted it back together with the base before installing it in the truck. Now that it is in the truck I find I do not like it. The back is straight up vertical and the seat will not slide back nearly as far as the old one. The end result is I feel like I'm up against the wheel and there is no support for my lumbar.
On the plus side the seat is higher on my back than the old one was by about 2 inches.
I will try to figure out a way to measure and compare the seat bases better. They are quite different so it's not as easy as it would seem to compare them. Apples vs Oranges if you will.
On a different note the rear end has been repaired and reinstalled without problems. There is however a more noticeable clunk when going from forward to reverse than there used to be. It could just be me being paranoid. Lots of changes of late with not many miles driven.
Just a quick tip. When it came time to reinstall the Unbolts on the axle the bolts had taken a set and the ends were too wide to go into the axle mount holes as well as the rest of the brackets and trailing as arms. I had to use a woodworking clamp to squeeze the bolt ends narrower to get them to drop in. I don't have a large enough vice at the house to squeeze them together so I had to make do. The clamp was just able to get the 1/8" or so needed to get them to drop in without damaging the threads.

Re: Working Man's Burbon
 

I’m happy to hear the driveline saga is all but over. That really sucks that companies think that behavior is acceptable. It also make me REALLY appreciate my local driveshaft shop!

Re: Working Man's Burbon
 

I may drive down your way for my next one!

Re: Working Man's Burbon
 

First off big Hurrah for djeCST and his thread on turn signal switches! :metal::metal::metal:

http://67-72chevytrucks.com/vboard/s...d.php?t=711090

Yesterday I noticed the turn signal lever seemed kinda floppy and vague. Well today it was loose enough to start randomly honking the horn. I had to pull over and unplug the horn relay just to get home safely. With all the disgruntlement in Portland these days one doesn't want your horn honking randomly.
My first thought was the screw had backed off, which was partially true. It had gotten loose but, it was because the threads had pulled out. (Photo #1)
I have to apologize for not getting photos from start to finish on this little repair. But I have harvested some from djeCST's thread and others. Hopefully they don't mind?

I used djeCST's thread to figure out how to disassemble the switch from the housing.

So the turn signal cam pivots on a pot metal pin. (Photo #2 & 3 blue circles) The end of that pin is threaded and the screw that secures the signal lever in place goes there. To repair this I cleaned the hole out and filled it with JB Weld (Did you know a farmer in Iowa fixed a tractor block with JB Weld?) Once it had hardened I filled it smooth (Photo #4) and drilled and tapped it for an 8-32 screw.
The screw that was in mine was the black self tapping one. (Photo #5) I have no idea if it is the correct screw. Although it look like the one in the photo I found. I replaced it with a regular screw with a square end and used a bottom tap to get more threads to the bottom of the hole. All this was iin hopes that with more threads it won't pull out again, or won't pull out before I find a bad switch with a good pin. I also considered drilling oversize and tapping it for a 10-32 screw but the wall thickness would not be very much and I would also have to oversize the hole in the cam and the lever too.
While I had the wheel off I greased the upper bearing and cleaned and lined the switch. It is amazing how much dirt and debris gets inside of the housing.
Once back together the switch works so much smoother than before and it doesn't honk either. :lol:

Re: Working Man's Burbon
 

Do that!
Walker Driveline in Talent, OR. Great guy that always keeps my budget in mind. I have to stop myself from calling it “Walker Texas Driveline” lol

Re: Working Man's Burbon
 

I rolled out this morning to do more tuning of the front suspension. Earlier I had trimmed the cups to get more air pressure at ride height to make the ride better. It helped but it wasn't enough. After I pulled the driver's side cup out I marked the centering ring height and how deep the cup was on a piece of metal. (Photos #1&2) Then I measured the difference to be removed. (Photo #3) The ring I had welded in the control arm to keep the bag centered was just under 7/8", so I made the cup depth 15/16".

In addition to this I wanted to cut the bump stops down a bit. Currently when you hit a deep pot hole the wheel drops and then before the shock can catch the weight the bump stop slams into the crossmember and the whole truck is jarred. Photo #4 shows the bump stop bottomed out. (Ignore the green circle) As you can see there is not much room and that short bumper doesn't have much in the way of cushioning. I should have engineered it better from the beginning.

Once the driver's side cup was reinstalled I removed the bump stop and the jacked the truck up on the control arm to see how much of the metal base I could remove and still have the bumper stop the arms before the airbag became the bump stop. Something all the air bag manufacturers say is to be avoided. I used a drill bit to determine that the gap was now 7/64" (Photo # 5)

Once numerous measurements were taken I decided that I could safely remove 1/4" of the bumper mount. I am hoping that this 1/4" and a higher psi at ride height will reduce the tendency to bottom out on everything but the worst bumps.

During all of the up and down with the bags the driver's side front valve started not shutting and allowing the bag to keep inflating. I have had this happen before and I had to tear down the valve and replace the O-rings. It will take about 2 to 3 hours to replace the bad O-ring and get everything back on line. Well that's going to be a job for another day as it now is working correctly and I need to get the rest of this done.

Re: Working Man's Burbon
 

Now I had a developed plan it was time to do the passenger side. This time I removed the shocks to get easier access to the cup. When I went to remove the shock from the I discovered this! (Photo # 1.) The bag has been torn up in 2 places. I had been maneuvering around in a friend's back lot a week or so ago and must have gotten something jammed up in there.

Sorry to say but this is the last straw. These damm bags are coming out. The problems never seem to end, and I really do not like whipping the truck into a turn a 55 mph and it not handling as expected as one of the bags has lost 5 psi.
I didn't see any need to finish the bump stop modification or to cut down the passenger side cup. I buttoned it back up and will hopefully I can drive it until I get the springs.

Time to figure out what springs I need.

Re: Working Man's Burbon
 

That’s too bad about the front bags. I totally get it though. I’ve always been reluctant to bag the front of mine for fear of the same.

Re: Working Man's Burbon
 

Time to move on. I picked these control arms up a few years back at the Portland Swap Meet. They were part of a bunch of stuff in a package deal. I'm probably in to them 50 or 60 bucks. One is set up for some kind of air bag. Time for the blue wrench! 45 minutes later it's ready to have the ball joint pressed out.
I'm willing to bet the ball joints and the bushings are generic offshore units. I will reuse the Moog pieces from the old arms. That will also save me from having to re-index the control arm shafts. And with a little over 20k miles on them the Moogs should still outlast the other ones.
Now just waiting for the springs to arrive.

As a side note the shortening of the cups that I did in the previous posting did in fact stiffen up the front suspension feel. It is more of a change than I expected. The truck now has more of a 70's Trans Am feel when entering a turn. I believe that it is possible that with the bags being stiffer at a lower height is keeping the suspension in a sweeter spot for the alignment.

Re: Working Man's Burbon
 

It's a moot point now, but Slam Specialties bags have an internal bump stop so you can totally ditch the OEM one. I haven't put any serious miles on mine but I'm banking on the internal stop being sufficient!

Re: Working Man's Burbon
 

I put the time and energy on the bump stops since I had been advised not to rely on the internal bump stops. Apparently over time little bits of material from the bump stop will break off and make their way out of the bags and into the dump valves, eventually causing them to malfunction. This may not be a concern for vehicles that aren't driven daily, but I felt it was worth the work to avoid the issue if i could.

Re: Working Man's Burbon
 

I hadn't heard that, in fact the internal stops were a selling point of the bags for me! After some digging I came across this on their site though:

"All Slam Specialties air springs are supplied with an internal bump stop. This has been designed into the air spring to protect the rubber layers when fully compressed. If a vehicle is using the internal bump stop on the air spring as the primary bump stop all defects arising from this type of installation will not be covered under warranty."

I guess I'll fab up some adjustable bumpstops next time the control arms are out...

Re: Working Man's Burbon
 

I'm currently trying to come up with a creative but not gawdy way to put bump stops on my MII on my 40 Ford. :lol: Maybe should have left it a lone. IDK. haha

Re: Working Man's Burbon
 

I have discovered that bump stops can be a big pain. At least with the air bags and tuning ride quality on my Burban.

These finally showed up yesterday! I wasn't expecting to see a pair of bump stops with them. Down the bump stop rabbit hole again! :lol:

I went with the 2 inch drops as the other option was 4 inch ( I wanted to stay with Hotchkis as I have had better luck with them in the past over others)
I know that they will sag with time. If they just stay too high maybe a larger engine would solve that. :lol:

Re: Working Man's Burbon
 

Iron headed BB will fix you up! :)

Re: Working Man's Burbon
 

Picking back up where I left off in post 678. I want my rebuilt seat to have a taller back so I am cutting 2 backs to make one. First step was mocking up where I wanted to be. Which was 3.5 inches higher than factory.
It was important to make the cuts low enough on the bar to avoid the deformed areas below the 90 degree bends. It is important to be able insert a piece of tube inside to strengthen the weld joint. I also thought it better to have the joint as high as possible since there would be less leverage on it than there would be at the bottom.
After deciding where I wanted the joints to be I added an extra inch in each direction just in case. I took my 9" grinder with a cutoff wheel and had things apart in no time.
My caution in the layout paid off immediately when I looked at the cuts. For some reason there are tubes installed inside the tube frames. (Photo #2) They seemed to be in the bends and at the bottom where the flattened bends are. (I have to admit I didn't spend a lot of time examining them.) I was lucky in that I only had to adjust the location of the joints by 1/2 inch to be clear of the inter tube.
Once I had ground the ends square, I cleaned up inside the tubes with a file to allow my stiffeners to fit. The ID of the tubing is just over 7/8" which isn't a real common OD for tubing available on a Sunday afternoon. Fortunately I managed to scrounge up two 1 1/2" long spacers, which I feel will work fine but I really would have liked some longer ones.
I drilled some holes to allow me to plug weld the spacer to the tubing as well as the weld at the joint. I'm shooting for a 1/16" gap between the upper and lower tubes that will allow the weld to penetrate all three pieces.
My spacers may look a bit rough but that came from grinding the galvanizing off so I don't poison myself welding it up.
The rest of the afternoon was spent removing paint and rust from all of the wires on the back that will have to be welded.
Oh and I ground down the ends of all the wires where they are welded to the frame. Every one of them had poked through the upholstery. (The last photo.) I want to avoid that in the future.

Re: Working Man's Burbon
 

Another major truck failure happened on Monday. I was driving down the road at 40 mph the truck died. Fortunately I was able to coast to a nice safe place to troubleshoot the problem.
After verifying I had fuel pressure, and the accelerator pump was spraying fuel. I pulled a plug wire and found no spark.
I ran a jumper from the battery to the distributor and still nothing. So I called my buddy and he brought me a HEI module and a complete distributor. By the time he got to where I was I had the HEI module removed. (I love my Gerber Multi-tool) I installed the module he brought to no avail. So I pulled the distributor and installed the spare distributor he had brought and the truck fired right up.
At this point I don't know if the module he brought was also bad or if the coil in the HEI failed. It doesn't really matter at this point as I am done with HEI's. I had planned to remove the HEI since I got the truck, and had finally started on its it's replacement several weeks ago. All that was left was to have my buddy curve it. After he came and rescued me my distributor went to the front of the line.
I picked it up Wednesday night and will get it dropped in hopefully Saturday. If the heavy rains predicted don't happen.
Early cast iron distributor with a basic Pertronix point replacement installed.

The upside was I met several really nice folks who stopped to see if I needed anything. One gentleman in a 51k mile 1966 Super Sport Impalla stopped and talked for a while. His Impala is a truly original car that looked better than some restored cars. The only non original parts on the car were the interior door look knobs and the radial tires. It had the 283 four barrel engine, dark blue poly paint, with a black interior. He bought it from the son of the original owner. Including a box of paper work that had the payment coupon book. The payments were $83 & some change a month.
Not an actual picture of the gentleman's car but one I found on the interweb.

Re: Working Man's Burbon
 

Glad to hear it was a fairly easy fix. I have had a Pertronix kit in my stock 327 distributor in my '36 Ford since (I think) the early '80's and have never had a lick of trouble with it. I rebuilt the 327 a couple of years ago and never touched the distributor. Just stuck it back in the engine and roared off into the sunset....:).. Still runs like a champ.

LockDoc

Re: Working Man's Burbon
 

I finished the seat back fabrication. In addition I got the broken welds on the seat base rewelded. Now to decide whether to have the frames powder coated or just painted.

Re: Working Man's Burbon
 

I got my new distributor installed. Converting from the HEI meant I had to install a new coil. This ended up being the most difficult part of the conversion. I only had a couple of Pontiac brackets, one AMC, and no Chevy ones. None of them fit particularly well, but I did modify one of the Pontiac ones to work using one of the back intake manifold bolts. Painting the bracket became rather annoying. As is the case nowdays the can of paint quit spraying during the second coat. . After messing with it for 5 or 10 minutes I grabbed another can of black paint and finished the 2nd coat. But when I checked on the paint 30 minutes later I discovered I had sprayed lacquer over enamel. Now I had a nice wrinkle finish on half of the bracket. Uggg! It was time to start over.
I am really getting tired of spray cans that are won't spray all of the paint in the can unless you use it all in one shot. It never used to be a problem if you shook the can well before using and kept the nozzles in a jar of thinner between uses. Nowadays if you leave the nozzles in the thinner they swell and don't fit the tube on the can. And with the new and improved cans that spray upside down you can't clear the tube of paint. Another product engineered to fail to improve sales. Just like rubber bands, tooth brushes, and of course automobiles.
The distributor is an early 60's cast iron unit with a Pertronix Ignitor basic unit installed. (Photo #1) This made wiring simple. Just 2 wires on each post of the coil. I had to change the lugs on the power and tachometer leads to ring terminals before hooking them to the coil.
I like using the early distributors as they have larger shaft bushings and if your running points the cams are ground more accurately and were heat treated better than the later distributors.
Before I pulled the distributor out I set the crankshaft at TDC on the firing stroke. (Photo #2 More on why it's at 8* BTDC later) You don't have to do this but it makes starting the engine easier if you're working alone like I was.
I used an MSD HEI conversion cap which other than the aluminium posts I am quite happy with. (Photo #3) The rotor is a solid unit with no flex or play in the mounting. It came with a nice go/no go guage for the center contact or tang as they called it. (Photo #4)

Re: Working Man's Burbon
 

Once I had the new distributor in the block, with the rotor aligned with #1 cylinder, it was time to preset the timing. This is where the 8* BTDC mentioned previously comes into play. It is my initial starting point.
With the crankshaft at 8* BTDC I turn the distributor so that8 #1 plug wire is clockwise from where the rotor is. About one plug wire works well (Yellow arrow in picture) I hook up my timing light and while aiming at the timing marks I slowly turn the distributor counterclockwise (blue arrow) until the timing light flashes. I stop turning the distributor and that is my preset timing. This allows me to hit the starter and have the engine start immediately so I can then set the timing properly. This works well when starting an engine for the first time.
Once started and idling I set the timing at 12 BTDC. Next step was to shut the engine off and restart it to check how it cranks over (looking for any possible kickback or slow turning of the starter indicating the timing being way off or plug wires out of order).
With nothing of concern noticed, I revved the engine a couple of times and watched to see if it came back to the same idle speed every time, which it did. It was at this point I noticed that my A/F guage was reading about 1 point higher than before. The reading had always been around 12.2 to 12.4 with the old distributor. Now it was reading 13.1 to 13.3 (Disregard the .8 in the photo as the numbers jump around and I just happened to take the photo as it flashed a high reading.) The new ignition system is obviously giving better spark than the HEI was. Time for a test drive.
The test drive revealed that I had some pinging at part throttle acceleration. I have suspected that my timing light isn't giving me accurate readings since the last time I used it. The 12* on the timing tab and where my light was indicating 12 degrees didn't agree . Whether it was the cheap aftermarket timing tab or the light I didn't know. We had set the tab to TDC by measuring piston travel. (We didn't use a degree wheel to check the accuracy of the tab or the cam timing.)
It is an adjustable light with a knob on the back and over the years I think the sticker with the degree indications has moved. So I drove over and borrowed a friend's light and sure enough it showed that I was at 17 degrees not the 12 degrees my timing light indicated. Problem detected, but how to repair the light has yet to be figured out.
Anyway with that figured out the truck was no longer pinging. With some fiddling with the idle screws the A/F ratio came up to around 13.8 to 14.2 better, but I couldn't get it to 14.9.
The idle was a bit too high and the idle adjustment screw is not holding the throttle plates open. It is as far as it can go.
So now it's back to the idle bleed adjustments that we did when the Qjet was installed. The idle bleeds in the carburetor are still too large and need to be smaller. This will will reduce the amount of emulsified fuel drawn into the idle circuit for a given amount of air flow past the throttle blades. Thus the engine will idle slower. Ideally I want to reduce that amount of fuel so I have to turn the idle set screw in about 1 turn to get the idle speed I want. Once I get to that point I should able to get the idle A/F ratio to 14.9.
With this gain in idle fuel usage and the Gearvendor overdrive I'm sure to be getting 13 MPG in town. :mm:
Time to fill up and drive. :lol:

Re: Working Man's Burbon
 

Good deal! You've been a busy man....:)

LockDoc

Re: Working Man's Burbon
 

Oh boy! And I've been working on a 68 Lemans to sell. Oh and the winch project too.

One more note on the distributor swap is that my factory tachometer only now reads 75 or so RPM high at idle and about 300 at 55 mph. With the HEI it was about 300 high at idle and 800 at 55.
A nice unexpected benefit. I may try and adjust the tachometer to see if I can get it closer.

Re: Working Man's Burbon
 

I would think there would be enough adjustment to make up that difference. Let us know how that goes.

LockDoc

Re: Working Man's Burbon
 

Will do Doc!

Yesterday I put the WMB on jack stands and removed the front air bags. I was pretty much A&E most of the day so I did get much in the way of photos. Just the one of using a Porta Power to pop the lower ball joint out of the spindle and one of how to modify the lower control arm if you re-index the control arm shaft for caster.
The photo of removing the lower ball joint was taken after the joint was popped out. Staged if you will. I used an deep impact socket to clear the upper ball joint nut and stem. I pumped the Porta Power up and put some soft heat on the spindle where the ball joint taper is and a couple minutes later the joint popped free.
I had notched the control arm (Blue circle in photo 2) so it will clear the saddle on the crossmember. (Photo #3) I had done this on the other control arms but I didn't seem to document it at the time.
Doing the caster modification on the lower control arm shaft it moves the arm forward and it will contact the saddle.
My new control arms had the wrong ball joints installed so I swapped them this morning and everything was ready to put the new springs in and button it up.
Unfortunately Hotchkis put the wrong springs in the right box, so no buttoning up of things! Ughhhh!
I called Jegs and they didn't have any other springs in stock and I wasn't going to have the truck sitting on jack stands for 7 weeks waiting for an other set from Hotchkis.
I ended up ordering a pair of Classic Performance 2 inch lowering springs from Summit. I went with 2nd day air so I might be get the truck back on the road by Saturday. I have no experience with this brand of springs but they were in stock. I hope they work out well, but it's still 2020 so I'm not placing any bets.

I need to thank Chevy_Mike for his method of installing the control arm shaft bushings. Much easier and faster than going by the book. When I was finished the torque came to about 130 ft. lbs. Slightly over the 95 ft. lbs. the manual calls out for used parts.
I found it in this thread. The 2nd post.

http://67-72chevytrucks.com/vboard/s...d.php?t=508095

Re: Working Man's Burbon
 

Amazing build. You have put in some major love and effort into this ride! Builds like this help motivate me to get some of my projects rolling. Keep up the great work!

Re: Working Man's Burbon
 

Thank you, I really appreciate your kind words.
Especially after yesterday's spring debacle. :lol:

Re: Working Man's Burbon
 

I got the air bags replaced with the new springs along with new outer tie rod ends and a pitman arm. Removal of the bags and the control arms was pretty uneventful.
The reassembly took quite a bit more time than I expected it to. I had to swap the ball joints from the air bag arms as the ones in the new control arms had the wrong taper.
Then the upper shock mounts I had installed would not work as they were, so they had to be removed and new holes drilled to get every thing to work. (The shocks hit the crossmember when compressed.) Drilling those holes was a pain the first time around and nothing was better this time.
When I went to bolt the right wheel on I realized that the outer edge of the new control arm stuck out too far and was hitting the brake rotor (Photo #2 @#%&#$= aftermarket parts) so instead of just letting it wear in I felt it would be better to grind it off with a grinder instead of the brake rotor. :lol:
After scratching my head and cursing a bit I concluded that removing the hub and rotor would be the easier than popping the ball joint out of the spindle to get access for grinding the end of the arm off. I taped a rag to the spindle to keep the grit from the grinding away and to make sure I didn't accidentally hit the spindle with the grinder.
Just an 1/8 of an inch was all that was needed to have enough clearance. The whole end to the arm had to have the 1/8" removed so the rotor cleared when steering. (Photo #3 yellow lines indicates the area I ground off.)
The drivers side had plenty of clearance between the arm and the brake rotor.
Once that was taken care of and everything was double checked, I went for a test drive. Everything seemed to be good on the test, but I will take another look at things in daylight tomorrow.
I still need to remove the air lines and get the front end realigned. And I don't have the bump stops for the lower control arms either. The ones I had turned out to be for something else.
As it was after dark when I finished I dont have any pictures yet.

Re: Working Man's Burbon
 

OUCH!!!
My test drive didn't go as smoothly as it seemed. (Photo #1) I thought 5/16" of clearance would be enough, but obviously I was mistaken!
Doing the caster modification to the lower control arm moved the lower shock mount forward causing the problem. I had forgotten that was the reason for the shock mount modification on the old control arms.
I fabricated some new mounts. Photo 2 shows the spacer I used to set the distance between the two tabs of the mount.
Photo 3 the completed mounts. And last one of the new mounts installed with a ton of clearance. I turned the lower part of the shock 180 degrees and will run them for a hundred miles or so just to be sure nothing touches.
The upside of this is that I haven't been happy with the shocks for some time so I'm looking forward to getting better ones.
I forgot to mention I also installed new outer tie rod ends and a new Pitman arm.

Re: Working Man's Burbon
 

Well with a couple hundred miles on the new springs I am happy with the decision to replace the bags. Not once have I slammed into the bump stops jarring the truck. I did miss the ability to drop the truck when I washed. But such are the trade offs.
I still need to get the correct bump stops installed. I may also cut 1/2 a coil off the springs once I'm sure they are done breaking in.
The shocks have become more noticeably inadequate. I don't know if it is from the damage to the one side or if the air bags worked better with these shocks than the springs do.
Another thing I noticed is the truck leans a bit more in corners than before. After some thinking have decided that is because when I modified the old lower control arms I moved the sway bar end mounts about 1 inch closer to the front. Which in essence shortened the lever arm of the sway bar. Cheap sway bar upgrade. Woo hoo!

At first I wanted to move the mounts forward to regain that stiffer bar response, but I would like to find a 1980's Trans am or IROC rear sway bar for the rear axle. So after that is done it would be better time to decide if I still should move the mounts.