Okay, now I am confused :confused: . I am about to show my ignorance on this subject. Also, it only applies to 47-54 1/2 ton 3100 series trucks (maybe others, I dunno) It is my understanding that the kingpin is about .002 smaller in diameter than the inside diameter of the bushing. The knuckle is about .002 bigger than the outside diameter of the bushing. I also thought that the outside diameter of the bushings that came with the kingpin set (standard OR oversize) was the same and only the inside diameter changed. When using the bushings that come with kingpin kit (standard OR oversize), no press fit (or tool for that matter) was required and no reaming was required as it was "pre-reamed". Aren't these bushings supposed to "turn" inside of the knuckle? (dumb question: How can they be reamed inside the knuckle if the bushings are turning?)
Just to muddy things up some more, several of my buds have recommended making a one-off custom bushing that HAD to be press fit in the knuckle and HAD to be honed to fit the oversized kingpin as they do not like the floating bushing design. (Of course, they all drive f***d's, so what do they know

)
Any opinions about the one-off custom bushings?
I won't be responding to this thread any more as I may be in over my head!! So, Thanks in advance.