I was hoping @White Stripe would chime in. He had some good info in his build about lining them up. I used the Aqualu aluminum half doors. And I will say it took some time adjusting to get them to fit in the opening nice...
That would concern me that it wouldn't be on the shaft far enough. Only one time have I had a P.S. pulley come off on its own. On our 04 Duramax. I put loctite on it when I reinstalled and it hasn't come off again.
Can you shim the pump back more?
I too love the color choice!! Now seeing some cement grey ones part of me wishes I would have done that instead of keeping it the factory color...
On my body mounts(I have an Aqualu tub as well), I ended up having to use 2 different thicknesses on the cowl mounts to get all the body panels to...
Glad to see things have been well!! Looks like an epic family trip as well! My windshield frame must have been a twin... Pain to fix... But like you said, easier than hens teeth.
That's a big negative on any instructions... It came with one sheet of paper, but vague would be an understatement. I will say, it is pretty straight forward. A couple things myself and other have posted about not liking is the bolts are all SAE. Not metric. The bolts and washers are stainless...
I didn't even know those supports were behind the cowl lowers!! Mine were all taken from the cancer long before I saw it. Nice work, keep up the good fight!
I did my cowl before I had my Aqualu tub. The pinchweld next to the cardboard needs to be trimmed more to clear the mounting surface of the tub to cowl. The cardboard is the thicker steel that I did. I used 1/4 in. But, 3/16 would have been suffice. 1/4 is just what I had around. For the bottom...
I welded in a thicker plate on the bottom of the cowl where the aluminum tub bolts up. Since I see yours needs attention, you might want to do that as well. I did bolt mine together this week and it is very stout.
Unfortunately kinda the same story here. Summer and work are real time suckers away from working on the 40.. But, like you, I am back at it!! I am planning to have mine on the road next spring. That's the goal anyway. Thanks for asking.