twisted minis
+1y
No, I won't trade you bushings for those heims. IMO the heims FBI uses aren't worth anything. Sorry. I don't know where they are made, but I was impressed by the amount of slop in them when new. And also by how quickly they wear out.
1x1 will be fine to mount the tank with. I pay about $.85 a foot for 1x1 .120 wall. 1x2 runs about a $1.20 a foot.
As for a 4-link cross member, I like 2x3. Its plenty stout in all directions. And if is has a "notch" to clear the drive shaft then it will still be strong enough in both directions. I would use .120 or .188 wall. A 20 foot stick is around $90. As far as how many cross members, I like to have one behind the cab, at least one on the notch, and one at the very rear of the frame. One between the notch and rear is good but not necessary.
The brake lines. If you need a longer flex line, you will have to buy a custom line, or find something from a different stock vehicle that will work. Don't try to mix Standard and Metric fittings and lines, unless you want to flare different ends to make it work.
What you are talking about is Zing the back half. I've seen this done, and I really don't like it. Sure, you don't have to build spacers for the bed, but it leaves a lot to be desired. Its more work to Z it and keep it straight. You may as well just back half the truck at that point. I still think you would be better off notching the truck and building spacers. This will also allow for more protection for your gas and air tanks. They won't just be dangling below the frame. You can notch a truck and raise the bed floor just the same, Marcus has some good picture sin his project thread of his.
The link tabs, its not unnecessary. If you want a low profile setup it will help. You just have to make sure you are still setting the geometry up correctly when doing this, because it will change your Instant Center location and raise it up a bit. Which isn't necessarily a bad thing, but you don't want to make it too high. This is just something you need to consider when building your setup. Another thing to think about, would your bag mounts or shocks be higher than the tabs? What about the notch and the differential? If so, the bed has to be above those anyways.
Also when you are making your 4-link mounts, and attaching your cross members to the frame don't forget to plate a good portion of the frame in the area first. Import truck frames are thin on the inside wall, and they tear very easily.