decided to go with a dually rear-end for my #project52 ... so traded a 8.8 for a sterling (ford) 10.25 which has 3.5" axle tubes. i had custom u-bolts made while i was at denver spring picking up new center pins. i asked for 3.5" bend but when i got home these are closer to 3.75" so there would be a bit of play around the housing. obviously they'd be snugged up nice and tight after install, but just want to make sure that won't be a problem if there's a bit of room on either side.


while we're at it: any tricks for removing old bushings from the original spring eyes?

thanks.

 

On the bushings I used this:
1948-56 Ford F-100 Bushing Removal Tool For Rear Spring
with heat and a big hammer.

For installing them back I used threaded rod with big washers and nuts. I kept the bushings in the freezer to shrink them and heated the spring eye and they went in slick.
Here is a picture of the tool I used:


I'm sure there are other experts that would be better suited to answering the u-bolt question. I would think you would want them as tight as possible against the springs.

 

I'm no expert, but that's only 1/8" on either side and that doesn't sound too bad to me. Like you said, it gets snugged up tight. Once you've put a few miles on make sure everything is still tight. I used an old socket the same diameter of the bushings, held onto it with a vise-grip & pounded. Didn't take more than a few swings on each one.