A few teaser pics...
The axle and springs, all rebuilt and mostly painted up.
Outer hubs. Nice part about this axle is that it has the same 6x5.5 pattern. Uses these smaller 7/16" studs, though. If I changed nothing, I could just put my current M12x1.25 spacers on it to adapt the thread pitch, but I will be changing these to use M12x1.25 studs.
You can also get an idea of how the rotor is attached to the backside of the hub (the wheel studs press into the rotor, which has a tall enough shoulder to also press fit into the hub.
Backside of the hub and knuckle. No space to squeeze an ABS sensor in.
This is the idea on how to incorporate ABS into the axle:
These are parts by a guy/company called THOR Parts. Very clever solution where he modifies the backside of the hub to accept a tone ring, machines the hubs down so Hummer H3 rotors can fit over the hub (note the studs pressed into the hub first), and then adapter plates to hold H3 calipers and a GM ABS sensor. Again, I plan to keep the R50 caliper and hopefully the 45° angle on the ABS sensor leaves room. End result should be something like this:
GM 1-ton TREs. Pic doesn't do justice on how fat these things are. The treaded ends are 7/8", compared to the R50's 14mm (9/16") threads. And these may still be the weak link in the steering!
ARB and 5.13s installed, new bearings, slingers, shims, everything:
Beefier diff cover, nice deal on it from a local guy.
Mock-up of leaf placement:
The perch width on the axle is almost perfectly the same width of the radiator crossmember, so the spring would reside almost perfectly under the wheel well skirt, directly under the subframe spacers so to speak. Notably, when using the narrow-track D44 I'm using, it wouldn't leave a lot of space for a conventional coil spring between the tire and wheel well, which is one reason I like the leaf spring approach (coilovers aren't cheap). Less of an issue running the wide-track version, though.
I do plan to retain the sway bar and I have a pretty good idea on how I'll achieve that.
Another downside to using leaves is the loss of clearance up front in small section. I'll likely lose a little departure angle unless I move the front hanger position back. With the low SAS, another issue is just exposure to the axle and steering. The tie rod will reside above the springs, but still be fully exposed in the center. I've hit plenty of obstacles with my skid grate, so it'll be a concern. Could go to full high-steer, but it's costly and doesn't do anything about the axle still be exposed. (Notably, these issues exist for any straight-axle truck, regardless of suspension type.)
The rear mount will be interesting. The chassis starts to widen halfway between the rear subframe mount and where the leaf eyelet is, leaving mostly nothing directly above the eyelet. The transmission crossmember holes are still a good 12" past that, and there's no useful existing bolt holes and a bunch of overlapping sheet metal in that space (i.e., around where the OE jack pad is). I imagine I'll need to get a lot of that flattened out and cleaned up, then will probably weld in some sort of support plate. I'd like to tie it in with the cross member if possible.
You can also see that my CV boot has given up the goods and slung grease. I don't want to deal with that any more.