That is funny, because the info that I got from people including Frankie is that the more oil or gas (depending on the type of shock you have) is what cool shock not a bigger shaft and the trade off is the weaker shaft. This make more sense to me. However, Frankie is not concerned with smaller shaft on an 80 because the design of the suspension puts very little lateral stresses on the shock if caster is right etc.
Yes and no. More oil is better than less oil, but once it is hot the heat need to be removed. That metal parts like the rod and the sleave over the rod act as a heatsink that takes the heat out of the oil.
Now if it were a leaf spring truck it would be a concern.
In fact Frankie has tested another shock that has an even smaller shaft that we were thinking about using. It has better cooling thus less fading and is smoother on washboard roads etc. But the Bilsteins have a stiffer feel initially so he felt that they would be a better choice for us as a daily driver on windy roads.
Yes, the Bilstein will be good for handling in your situation. That is why the are a good choice for sports cars.
As far as the springs, It was my understanding that the springs have a small variable spring rate section. This coupled with the better shocks is why if feels better on a loaded and unloaded truck. And the cold cut CNC method should make the spring hold up loader.
None of the photo's that I have seen show a progressive rate on the spring.I know the photo's don't show all, but the first wrap looks barely closer than the rest. Most progressive rate springs I have seen have at least 2-4 wraps that are wound closer.
