Much better. Standard steel plate does not come in .20 or .23. We will call it 3/16 (.187) and/or 1/4 (.25) Your measurements are accurate, just tolerance, burrs, fabbing dents, etc. Good job.
The "calculated" inside frame to inside frame is 35.64. The O/A measurement for crossmember you gave is 35.625. So that's close, like .0075-.0000 per side close, but will be OK with a little trimming.
The actual CL to CL number for the new axle brackets is a little over 38" if they are supposed to match the frame brackets CL to CL. The mockup will self locate the parts. The fact that the frame brackets are slammed against the frame sets up the alignment of the axle brackets. An exact 38" is not necessary. Probably will end up between 38"-38 1/4". Then the rest of the parts are aligned from that portion of the assembly. Don't forget the pinion angle requirement. Piece of cake.
Do a complete mockup using every part. Every bolt. Before final weld. That way you spot little things you didn't think of. I.E. missing parts, wrong parts, extra fabbing, other crossmembers, any trimming, brake lines, wheels, tires, exhaust, bed mounts, coil spring clearance, wiring, ebrake, stance, symmetry..........
If you use locknuts, use regular nuts for mockup. Then the locknuts at final assembly. Read both 47-54 and 55-59 online instructions as you go, to get tips.
Regarding the lower mount for the shocks. Did they give you the 55-59 3 hole extension tabs or the 47-54 style? you will need the 55-59.
Looks like you are all set for a great outcome once you get the new axle brackets.
For those looking for an update. NEVER BUY THIS KIT IF YOU HAVE A 3/4 TON. THERE ARE NO INSTRUCTIONS.
I will do a thread with pictures if it ever comes together. TCI sent new axle brackets to weld on in order to accommodate the brackets going on the outside of the frame. (I held off welding them on in order to fit everything together first (smart)). I roll my built axle into place with the old 33" wide welded brackets and offset it so that one axle bracket will at least line up correctly with the frame bracket. So i go into the instructions they included saying the 4-link bars should all be set to 24.50" in length. at 22" the 4-link bars fall apart..... None of the TCI instructions outline what to do here, so it's clear you're on your own to center the axle and angle accordingly with the 4-links provided. By my guestimation they should be just fine and likely at that 20" mark give or take.
Next comes the frame brackets. So i read 3 different sets of chevy 4-link instructions, all state "Determining left and right side brackets: The lower 4-link bar hole on the frame brackets will be further forward than the upper holes and the brackets sit on the outside of the frame rail." No big deal right? Well it is when they send you two of the exact SAME frame brackets. My passenger side bracket lines up just fine, but take the mirror of that and my driver side lower 4-link bar hole is behind the upper.
Another email sent off to TCI... This is almost becoming laughable if it wasn't setting me back so much and so often.
