I think I would modify the upper mount in a couple of ways.
Yes, you can trim the outer edge and maybe angle it in (you still need the material there for strength) but at the same time I would extend the mount inward along the line of the trackbar just to put more material around the bolt.
I would also use that as an opportunity to reinforce the whole configuration with a second layer of material or something like that.
Overkill? Perhaps. But a single weld along the two pieces of metal could be a weak link depending on the quality of the weld and if it's welded on the inside and other welding-stuff that I'm not qualified to suggest.
If doing those mods doesn't look like it's going to help clear the bushing any better, then like Todd said, you're better off just removing the extension completely, putting the bar back in it's old stock hole and then raising the lower mount higher on the axle with a riser.
While your '76/'77 upper mount is a strong piece, a riser could conceivably be even stronger.
Depending on what use you put your EB too then (hardcore 4-wheeling?), lessening the leverage on your frame there at the upper bracket is a good thing.
With supposedly 5.5" of lift (see comments below) and the appropriate tire size, the upper mod and riser option looks even better.
It's just that this is such a critical piece of "componentry" that you would never want it to fail. On the trail and especially on the street.
If you leave it in the current configuration then, and just remove some material, reinforcing it somehow would also be a good thing.
I can't say how much more of a bend there is in a 44 track bar vs one from the 30, as they were very close to the same, if not exactly identical. But it can't hurt.
I'm sure others here will remember if they're in fact different. I know we've discussed it but can't remember what was said about it.
Reason I even bring it up is that I've seen even the correct trackbar hit a diff cover before. Not very common, but does happen. Maybe someone can compare curves?
Is that really 5.5" of lift? Doesn't look that tall and you have very good (shallow) angles on the linkages. Yes, your track bar and drag link are not parallel, but since your track bar is quite a bit shorter, it's probably perfect.
Do you have any bump-steer issues on the street? Or does it steer and handle pretty good?
Any other late-model bits on your '71? Gas doors and the lack of the threaded J-bolt for the parking brake? The really big drum brakes on the back? No EVAP condensing tank behind the driver's shoulder?
Just curious.
Paul
