So I'm gonna get my rear leaf springs rebuilt on my '86 pickup. The shackles didn't come out too bad, but they are pretty rusted. Didn't fight with the bolt in the front, just cut it off. I can see just replacing the bolt in the front with a new one, should be ok. However I'd like to make new shackles for the back, but I see there is a shoulder on the bolts, to keep stuff from getting squished together I guess. Is there a way to duplicate this without welding a brace between the side plates, doesn't seen like there is room for that. Would appreciate anyone's comments and thanks in advance to those who reply.

don't know if this helps, but this is a picture of some shackles that ZUK made for me a coupleof years ago...

[img]http://i42.photobucket[/img]

If you aren't planning on running longer shackles, you shouldn't need to worry about welding in a x-section. The stock length shouldn't twist much if at all. You should be able to just run 2 pieces of 1.5"x 1/4" flat stock at the length and just drill holes in each end.

This is a welded set-up I did for my flatbed rig. The shackles are 3" longer than stock which yields 1.5" of lift. If you don't have access to a welder, you can bolt a center piece in and get the same result as welding.

If you have to get new spring bushings you will have to fab your own. I used some CJ bushings that I had to mill down using a grinder to get them to fit.

One option is to use a sleeve inside the bushing (some bushings come w/ sleeves).

Another option is a bolt and lock nut, tighten the nut to just compress the bushing and use it like that. I add anti-rotation tabs to hold the bolt head still inside the shackle and that helps keep it from loosening:



http://www.4crawler.com/4x4/ForSale/Shackles.shtml

i've run roger's shackles and poly bushings, they do the trick