Since the repairs were complete and the frame was coated and painted inside and out, I set about putting the PST PolyGraphite bushings in place and buttoning up the project.
The body sat down on all of the bushing washers at just about the same time except #3. I had a couple of washers on hand with a big enough hole in them to put between the top bushing washer and the body which filled the gap perfectly. A quick coat of paint on them and in they went. While the paint on those and the #1 shims was drying, I set about squaring the rear of the body up with the chassis.
It was 5/8s of an inch to the driver side at the axle centerline...so the body needed to move to the passenger side 5/16s of an inch. Ratchet straps did the trick.
I then tried to get the #6 and #7 bolts started...which proved to be a challenge. The factory bolts are 79mm long and pointed on the thread end, the new bolts I bought from Fastenal are 75mm long and square ended. I didn't think that 4mm would make a difference, but in many cases...it did. The trick I finally learned was to use a longer old factory bolt (cleaned up and threads chased) to line the bushing, sleeve, washers, and cage nut up...then back it out and then put the shorter new bolt in its place. In some cases the body had to be sitting on the bushings to get these bolts started. I finally got all of the new bolts in every place but one, which I had to use a painted old bolt that was still in good shape but had I to do this job again, I'd buy 79mm or even a bit longer bolts for sure.
I got the 4 back ones started and had to squeeze the body back square a bit more with the straps and then started getting the rest of the bolts in. Even with the lift it's a bear to get the #3 stub from the body down into the washers and bushing...especially by myself. I finally got my Dad out there to help me...he'd raise and lower the lift that was lifting the body while I'd line things up and get the bolts started. Once a bolt was started I'd move on to the next one. It went pretty quick after that.
Once all bushings, washers and bolts were in place and started, I checked the squareness of the body again and both the front and the back needed a bit more of a tweak. Again a ratchet strap hooked to the body on one side and the frame on the other proved to be the easiest way to nudge it over. Once square I set the body down on the bushings one last time and tightened all of the bolts up starting at the back working my way forward in a crisscross pattern.
I then reattached all of the cleaned up and painted bumper hardware and tailpipe hangers and called it a day. Still haven't put the front inner fenders back in but I have a couple other jobs planned that will be easier with them out.
I checked the fender ride heights with the car snugged down and back on the tires and all 4 corners are within an 1/8" of where they were before I started. If I bounce the front up and down and measure, the fronts are an 1/8" down and the rears an 1/8" up. If I bounce the rear of the car and measure, the rear is down an 1/8" and the front is up an 1/8". I'd say it's right on where it was before, just a bunch more secure in place and square.
Here's some pics of the snugged down bushings...
#7 Left
Think this is #4 Right
#3 Right
#2 Right
#1 Right
#1 Left
BTW, remember this picture of #1 left when the car is lifted on the lift and the front end of the frame sags under the weight of the engine?
This picture was taken of the same spot with the car lifted on the lift but new tighter bushings holding the frame up and in place.
Problem solved...