Most of that is good news. (I would be very happy if they say 38"). If the crossmember fits, good. Doing yourself, good. Not getting mad yet, good. It may just work out. Mocking up, good. You will know for sure then. Good work under disgusting circumstances. I commend you. You are correct to "be nice" so you get all the answers and new parts. Glad you have welder friend. You are correct that their answer makes no sense if they have said in writing to use the outside brackets. I think the axle brackets will have clearance unless the new diff is narrowed or something. thanks for now keeping us informed. Keep it up.
On the cut off, I would not necessarily try to cut exactly where weld meets tube. Stay back a ways and then slowly grind the left over weld. Do not get the tube hot. There are wheel bearings and seals that can get damaged if they have been installed. Keep cooling with shop air.
Some say I'm paranoid (I call it intuition and contingency planning), but I would not remove the axle brackets till this is all sorted out and mocked. You never know what TCI may come up with next.
Some of the shipping or management folks there are confused possibly because 55-59 1/2T and 3/4T frames are the same width. No need for two kits or mention of 1/2T, 3/4T.
The danger signal/RED FLAG is that they have no instructions for a 3/4T kit they allegedly sell. That is NOT possible or acceptable. It should have been on their computer long ago to print it out or link it. The only other living human I found that bought a TCI 3/4T kit was on Speedway Motors website and he said he got the wrong parts. A proper company would have a parts list. It would tell the employee what parts to build a kit. Each part would have a part number stamped on it and the assembly/kit would have a part number also. Does not matter if they are made to order. The fabber would have a drawing of each part (and the part number) necessary to make for a kit according to the parts list. BASIC manufacturing. This works even if parts are subbed out. I assume the founders of TCI have retired and the son's took over.
