CK5
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75 Jimmy build FOOLSIZE (time to wheel)

Wheelbase: 108" Width F/R: 89.5" / 88" 3 link -upper: 32" -lowers: 32.5" -vert sep: 8.5" -panhard: 38" 4link -uppers:38.5" -lowers: 40" -vert sep: 9.5" Front DS 1410 HADCV ride: 33" Rear DS 1410 ride: 38"
Just read through your build... love to the truck and glad you are ok. That was one hell of an accident.

Thanks man! We gotta wheel sometime! It has been a blast to build and an awesome hobby to get into. The accident was nuts but I'm nearly fully recovered and have been back at training for a week now. I'm set back about 7 weeks from where I left at so it's easy getting back into it so far
 
We're actually pretty excited about this project, we have changed the design of our shock towers, they are now built with the fewest cuts we could com up with and are tabbed internally with bolt sleeves to spread the load over more area of the bolt.

The Dana 60 presented us with the challenge of fitting everything in the small area 4inches. We figured that out also without changing shock geometry from our smaller axle kits.

We really appreciate that Zac was willing to be our guinea pig for this kit! We look forward to continuing to develop more products for this platform!
 
All of the brackets are weld on, we made some changes from our Dana 44 design to capture more weld area on the axle around the tube.
Here is a pic of the early stages of one side with the shock and link mount.
We use foam board in prototyping we have a cnc foam cutter, this allows fast turnaround for design and it's available in thicknesses that are damn near spot on for plate.
We had to figure out the cutting head but this was before that happened so the edges are feathered a bit. They now come out like you cut it with a razor.
IMG_8345.JPG
 
Time for a 3d printer chief!

We've got one sitting on the desk in my hobby room. The foam cutter is much more efficient for larger scale parts. Printing something like this on a 3d printer would take days, I can cut out the entire bracket set from foamboard in 10 minutes. Also very cheap for when I screw something up in the design. Sheet of foam is 99¢, vs a plasma cut piece of steel that could easily become a $50+ mistake...
 
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