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Reinstalled the small leaf back into the stack. That slightly raised the rear end, but not very noticeable. What is did do was increase the DS angle as needed per above discussions. DS 18.9* - Pinon 17.6* = 1.2*

Thanks. I had to remove all of the spot welds that hold the fender body to the fender mounting lip (where the bolts go). That was not needed to align the gap, rather to get the fender bow the same as the hood bow. It is a ton of work getting the hood gap right because every move changes the...

Great way to go! Just take your time and enjoy the build. I used self-tapping metal screws to hold panels together in place before welding then once perfect could spot weld the small holes. I had to add 3/8" spacers to the rear body mounts to get the door gaps right. Post some pics of the...

If you want all of the door, hood, and tailgate gaps perfect (3/16") then not only should you build it on the new frame, you should completely assemble it before paint. That includes the windshield frame, grill, and hardtop if your using one. The hood gap is really a work of art to get right...

This is a very low mount system.

@nvrstuk thanks! I’ll try to get piñon angle to 2°. I don’t have a GoPro to film but know what the axle wrap bump feels like under hard acceleration. It’s almost as if rear tires bump and skid slightly. I’ll go out and check that on a drive. I’m hoping the traction bars I installed keep axle...

@DirtDonk i agree completely. Sometimes the best info comes from real-life experience over the years. You and others are always a rich source of that and we all sure appreciate it! I called Tom Woods and asked about their diagram and language in the geometry article. Gent said key is to have...

Found this from Tom Woods himself from a 2015 post. This is the same graphic as on their store page in the geometry article.

So I also have now poked around the web and found lots of different opinions. About 50% of the articles/threads I read from across the truck world say zero angle between pinon and DS with Cardan at TC. Some say ensure you point pinon directly at the TC (that seems the same as in line with DS)...

I did install traction bars on both sid leaf packs. Looking at the Tom Woods Geometry article, here is a graphic. I understand the need for having the 1 or 2 degree of angle but apparently with the Cardan at the transfer case, if you start at zero degrees, it nicely absorbs any angle...

Not looking for perfection, but geez, these are pretty good numbers.

Received new rear driveshaft from TW today. I also added 4* wedges. After completion rear pinon is at 18* and DS is at 18.4*. So that is very nice given the double cardan at the TC end. As a summary, in terms of the rear suspension, I originally installed WH 2.5" SL and for door gap reasons...

Not sure if this would help your issue but last month when I installed Painless I found their pre-wired light switch wires were installed in the wrong slots. Once I fixed them, things worked as exspected

@Jdgephar could you post a link where you bought the lights and the docket connection.

Once everything is removed I bead blasted it and painted using gray metal silver paint. If you don’t have a sand blast cabinet you could just use an sos pad, prime and paint.

@chuckji I also used that door seal. Worked great. Used it on doors, top, and tailgate/liftgate. No glue required.

Thanks Todd. Will listen this tomorrow.

Measured at 34”. Have not raised piñon. Ordered 4 degree shims. Hope that works?? Looking at it with a tape measure it looks like the very most it could change is 1/4”. Certain the new DS can absorb that. Hopefully 🤞 @Shimmy did not believe front DS is making noise because have not driven truck...

So poking around underneath trying to see what might require attention. Grabbed ahold of the front driveshaft (which I completely rebuilt from yoke to yoke) and noticed there is a good 1/8" or more slop up and down at the slip joint. Assume not good. Went to rear driveshaft (also rebuilt...

@jamesroney I'll get those steps back on soon, right after I get the cow horns mounted to the grill...so much to do and so little time.