If he thinks 38" is the right number for the outside brackets and you think there is good space and he agrees that it is an option and all the other parts can work, cutting them off and touching up the paint is what I would do. He is ad libbing and shooting from the hip. Kludging it together. This is just my opinion. I have been there and Kevin has been there when we made mistakes at our Design Engineering jobs. We knew we only had one chance to fix a screw up and you better do it right with the least impact on schedule, price, safety, reliability.........
From my house it seems like cutting off the axle bracket and so forth puts the assembly back into the original design intent. I do see that this TCI fella is struggling and has gone nuts. If he agrees that all the parts will work at 38"........cutting off the old axle brackets is NO BIG DEAL. Let him know that you are willing to do the cut off if that's all it takes. The axle bracket spread is 36" for 55-59. The 38" is only 1" per side wider. Should not impact design. If the shock crossmember and track bar will work.
I know I have said this before but I'm saying it again. If they sell a kit for a 3/4T truck, what is the reason for all this talk about cutting notches, maybe getting a swivel to work if he does some more calculating and etc.? What happened on the initial order that they can't ship the required parts. Unless you have traumatized them about the already welded brackets. Why can't you start over with a 3/4 T correct kit? I believe there is a secret they don't want to mention. Like: they never had a 3/4T kit. If he does not agree to the 38"/bracket cut off idea using the other parts with no modifications by you, it's time to get all your money back. You will have built a good email string to use in your request. Showing his made-up fix that is untested, never tried, odd ride tech parts, wrong angles, no instructions available, machining parts and has extra work and risk for you. His emails are the rantings of a mad man. I mean that with all due respect. I've been where he is. In trouble. Do not do what he is planning. As Kevin says, you will go down a road to a nightmare.
Think of it this way.........NO NO NO NO OH NO NO No
I agree with you in looking at it again. Ive written back to ask if all the parts will work at 38" on the axle brackets.
Im getting to the point that im becoming more and more weary with whatever they're suggesting. If the parts don't work at 38" then it's obviously time to go a different route.
My only question at this point is if moving the brackets out to the 38"mark will end up limiting my wheel and tire size? At 38" it leaves me 7"to the back of the brake caliper. That brake caliper sits about 3" wide, so that makes it 10" from the mounting surface to the side of the axle bracket.
