on May 10, 2010, 6:11 pm, Daze wrote:

The problem was in the rear "shackle" mount. I had originally intended to use two use some 1/4" flat stock like shackles and weld it up solid to the side bar then bolt it in the bushings at the frame. problem is the space between the upper frame mount and the gas tank or the frame and the rear quarter panel is not large enough to fit a bolt long enough to go through the bushings and "shackle" pieces. Normally when installing new shackles you put the bolt through the flat bar and then slide one bushing over the bolt, from there the inner bushing is inserted in the frame and the opening for the bushing in the frame is big enough that you can angle the bolt, flat-bar, bushing assembly in to place. I will not be able to do this if both sides of the flat bar are welded to my side bars.

The solution is to drill a hole through the flat bar and my freshly fabricated side bars, bolt both the frame mount and the side bar mount in place and then only weld in the inner shackle plate up solid. that way it is held solid by the inner side, but the outer plate is removable so I can angle the shackle plat, bolt, bushing assemble in to place. besides, I like redundant connections and the welded section will have the support of the bolt and the bolt will have the support of the welded section.