Rear RS Kit Install Question

[divemaster5734]

Started the axle swap and immediately hit a snag.
The instructions say to use the three forward bolts from the OEM hanger, then drill the new forward holes.
There's two problems with that on the centurion.

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First there's a rivet from the cross frame brace on the bottom that's keeping the new bracket holes from lining up.

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I can drill out the rivet, then drill out the new bracket and run a bolt through, making sure the bolt won't interfere with the rear spring forward mount, which is one of the three horizontal holes.
That said, I knew they shortened the frame to put the Bronco clip on, I thought they did that at the back.
However

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It looks like they did it at the hanger mounts.
So even if I drill out the rivet the new bracket will be angled.
There's a spacer that goes in at the front of the bracket on the bottom, even so, the install pictures show a level frame, and mine is not.
The rivet is about 1/3 from the rear of the bracket.
If I ground down half of it the bracket holes would line up, so that tells me I'd need a countersunk hex bolt to replace the rivet to keep as low a profile as possible.
If I do as described, will that create a dangerous install?
I'd rather eat the $5k I have in parts than risk lives.
Hoping for advise from someone that knows more about suspension than I, as I'm mot well versed at all.

 

[Nero]

I don't think it would create a dangerous install, especially with it being torqued in correctly. What you'll probably have is bad ride height and extra springy suspension from the angle being wrong. Have you tried calling the manufacturer of the kit and see what they have to say about it? They'll probably know best.

 

[divemaster5734]

I don't think it would create a dangerous install, especially with it being torqued in correctly. What you'll probably have is bad ride height and extra springy suspension from the angle being wrong. Have you tried calling the manufacturer of the kit and see what they have to say about it? They'll probably know best.

Yeah, they're at SEMA until next week.
I'm not very impressed with their after sales support.
After looking closer that crossbeam is for the cab.
I'll run a couple spot welds at the frame then grind the rivet.
I'm concerned about the leaf spring placement as the '04 axles have a different spacing.
Until now I had blind faith in the kit, now I'm doubting everything.
Hopefully some lasers and tape measures will cure the apprehension.
I agree the ride height will probably change, thankfully it'll be the rear, and I think as long as the spring centers on the axle it'll sit an inch or two higher in back.
A little aggravating, but it could be a whole lot worse.
Not making a show truck, it's gonna play in the dirt.

 

[u2slow]

I don't think the hanger angle is a problem either. The hangers on my ramcharger look angled too, yet they are straight on the same era dodge pickup.

What's going to affect ride and handling more is changing the overall angle of the leaf spring (rear lower than the front).

 

[rreegg]

Just spit balling here but Is it possible to drill out a hole in the bracket to allow the rivet to fit within? It may not make a difference either way as there are other concerns and just how you want to skin a cat etc etc

 

[divemaster5734]

What's going to affect ride and handling more is changing the overall angle of the leaf spring (rear lower than the front).

I agree. I could probably add a block, but that opens up a posture issue.

Just spit balling here but Is it possible to drill out a hole in the bracket to allow the rivet to fit within? It may not make a difference either way as there are other concerns and just how you want to skin a cat etc etc

That's what I thought at first, but will have to MIG the cab support due to the spacer going in.
There's an aluminum spacer that sits on the bottom of the new hanger at the forward edge of the base.
Hopefully the pdf will attach, but it will leave a gap between the hanger and the frame.
Unless I didn't read the instructions correctly.
Couldn't attach correctly so just pasted the text:
A. Front Brace Forward
B. Install hanger using the three forward factory holes from old hanger. Snug up with three 1/2x1.25" bolts.
C. Slide Aluminum insert between frame and bracket, line it up with the forward 1/2" hole. Clamp Hanger to bottom of frame.
D. Center punch and drill out the three forward holes on the bracket in the frame, secure with 1/2x1.25" bolts.
Lastly, center punch and drill vertical hole through frame to secure the aluminum spacer and bracket referred to in "Step C". Use 1/2-2" bolt.

While the base truck is a '89 F350 Lariat crew cab, the Centurion modifications to the frame make the kit *****