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Picked up my circlips today (6 of them for good measure) along with a couple grinding bits for my Dremel. I'm going to see how easy it is to grind enough material away to get the shorter birfs in. I also rented the front end service tools from Advanced which made short work of the ball joints on the knuckle steering arms. Unfortunately I haven't been able to get ahold of anyone at Cruiser Outfitters the past 2 days so I don't think I'll get my new TREs by the weekend.
I've posted on this before, can't remember when/where, but the jist is that even if you've clearanced the upper and lower areas of the ball enough that you can slide in the birf, once you assemble and properly torque down the upper and lower knuckle bearing caps, the ball will compress and close the clearances some. Maybe enough to stop the birf from fitting. I had to do this on mine, disassemble, clearance some more, reassemble, retorque. Luckily for me, I got it right the second time, and the birf went in/out no problem.
IIRC, I used a die grinder *lightly* and finished each area with a 3" roloc brown disc to smooth things out. Good luck.
That's your steering center arm. It's adjustable and rebuildable.
So then I want to grind the housing down to fit, then bolt on the knuckle and make sure the birf moves around before greasing everything up?