My approach to reverse shackle modification is a little different then others I’ve seen.
· Measure from bolt (A) to bolt (B), this was 41” on Buddy.
· Measure the height of the truck body from the ground to the axle stop on both sides. This was 20 ½” on Buddy. (The only reason for this measurement is to see if the truck raised or lowered any after the mod is complete)
· Leaving the springs attached to a point (B), remove the shackle from the spring (you will need to use a bottle jack to carefully push the spring downward to be able to take the tension off the shackle bolts, and remove the front shocks to give the body room to move), then carefully remove the shackle pivot bushing housing (A) from the truck, trying not to damage it to much as it will be used later. (I used an air chisel to remove the welds holding the housing to the frame)
· Remove old bushing from housing and replace with new poly bushing. (You must use a poly style bushing or it will be destroyed when welding)
· Remove the old bushings from the springs at the front, and install new ones. (You should use the poly bushings since they are easier to remove and last 3 times longer)
· I used the following formula to figure out how long I should make the tubes. I had 9” shackles on the truck when I started and didn’t want to raise or lower the truck. The height I had was the height I wanted to stay with. The stock shackles are about 4” long, and knowing from past experience, each inch of shackle will only raise the truck ½ as much at best. So I divided 4” by 2 to get 2”. I subtracted this number from the shackles I had on the front of the truck when I started, 9” – 2” = 7”. This 7” is the length of the tube, approx. This seemed to work for me, but that’s me.
· Cut & fit in place a 3” x 3” x 7” x ¼” square tube to the front frame approx. where the old pivot bushing went.
· Drill holes in each tube 1” from the bottom, centered for the spring bolt, and notch the tube 1” from the bottom on the side where the spring exits the tube for clearance.
· Place both tubes in place, using the spring bolts to hold the tube in place on the spring. Lower the truck onto the tubes, then level each with a torpedo level. It doesn’t matter where the tubes end up on the frame, although they should be close to even on both sides, and they will end up resting a little forward of the old pivot housing. (By leaving the spring attached to the truck, this gives a base line from which to start. By leveling the tubes, this guarenties the springs will maintain the correct distance and spacing to keep the axle from moving forward or back during the mod.)
· At this point, I cut a few pieces of 3” x 3” x 3” angle and placed them behind the tubes at the frame for strength, and put a ¾” x ¾” x 6” angle along the side of the tube where it stuck past the frame on the side, overlapping the angle pieces.
· Weld the assemble securely, making sure to get good penetration to the frame. Also, watch for fires inside the frame, and don’t heat up the tube to much or you will melt the new bushing.
· Remove the rear spring pivot bracket and disgard (you will need to use a bottle jack to carefully push the spring downward to be able to take the tension off the shackle bolts)
· Using the stock shackles, place the two bolts thru the shackles and bushings so that you can spot the housing to the frame at the proper place. I sandwiched the pivot housing between the shackles with a vise grip, then measured from the pivot bolt at the front tube to the bolt on the pivot housing. When I reached 41”, I marked the frame where I needed to weld the pivot housing.
· Remove the new poly bushings from the housing and weld them securely in place.
· Wire wheel all welds, grinding them as needed to look as good as you want.
· Paint all areas that where worked on.
· Reinstall poly bushings in housing, reinstall stock shackles.
· Tighten all bolts, using hardened bolts.
· I needed to notch my front bumper so it would fit around the tubes, but it doesn’t look bad. Better than the stabilizer bar and the 9” shackles did.
· Enjoy the ride.