Ok, IT DONE !!!
What a fuggin bitch of a job.....
Used ALL your secrets, and I've got one of my own to add ....
Crimp the "U" bolts about 1/8" inwards.... it makes putting them into the holes SOOOOOOOOOOOO much easier !!
Forgot to re-set the alignment, so when i went for a test drive with about 1.5" of toe-in, it handled "weirdly."
Used the patented "Graham Hatfield" alignment method (String, axle stands and a ruler...) and its sitting really nice again...
Steering is a little "tight" now, but i expect it to loosen in the next week ....
I ended up taking 2 shims out of the rack and re-greasing everything heavily.....
Got the big tyres back on, flares and its all happy again!!
BIG THANKS TO ALL !!!!!
Especially you bnicho - couldnt have done it without your suggestions !
Cheers
J