So further drama with the "easy bolt on" drop spindles. The spindles were sent to the machine shop to ream out the tie rod holes so that they would they would A) fit the larger tie rod ends on my G20 and B) go from the top down rather than the bottom up so the steering angles would not be severe.
Special bits were ordered to accomplish the task, and we also found that the holes were drilled at an angle so that, when drilled out, they would be thin on one side. After careful discussion and observation, we proceeded to do the cut and thankfully everything matched up.
Next step was to simply bolt everything up and start driving - NOT.
When trying to put the rotors on I found two additional difficulties. 1. The spindle nut that came on my van DOES NOT FIT THE WESTERN CHASSIS SPINDLES. I am investigating what size the threads are actually cut at and will post the results. (They may be metric) I was foolish enough to call Western Chassis help line, but after a lengthy hold time I realized that you will be first in line for a specialist to pick up - FOREVER. They don't seem to ever pick up.
2. The rotors rub on the Western Chassis spindles and there must be extensive grinding to get enough clearance so that they will spin freely. This is using the factory G20 inner and outer bearings.
On further investigation I went to NAPA to identify the D52 calipers that are supposed to bolt up to the WC spindles. Everyone looked at me like I was crazy and came up with a laundry list of potential calipers that the D52 are supposed to be. Nothing would "bolt up" as mentioned on the WC website.
I patiently sat on hold with Western Chassis and actually got to talk to someone about the brake issue. The solution is not what I expected. WC makes a proprietary brake kit that does not use OEM parts. They have custom parts that only they produce to prevent competitors copying their design. They sell the complete kit with spindles, calipers, brake hoses, ball joints, rotors, spacers and nuts and bolts for around $700. You have to use their rotors and spacers or the calipers will not bolt up. If you buy just the spindles like I did, don't expect to see any of this explained on the WC website, as it is not.
The part number for the Western Chassis brake kit is SWBK-8D6370D
They will, thankfully, put together a custom kit for you. They sent me the kit less the spindles and ball joints for $485. At least I found out that I am not crazy and what I was told is not what really is.
Moral of the story - when you are out in left field expect to kit rocks (hopefully with shoes on) and not barefoot like me.
Nice to see you getting it together. When you go back to napa tell them D153! The G20 is a grey area with GM light trucks, The G20 is 3/4 light 5 Lug and the C20 is 3/4 heavy 8 lug. Nice to see someone doing all the same tricks I have considered for a lift spindle on my G30.
I have always used drop spindles in my projects in order to preserve ride quality. In this case, your suggestion would have been the better route. I have already started down this path, so I am financially committed to see it through. Thanks for the tip.
I have a friend who used dropped spindles in his van. He had to go to G30 springs to keep it from hitting the bump stops when he’d hit a dip or big bump. Basically the stock spring rate may not hold up to a lowered position.