HELP Blazer Brakes & G Outer Tie Rod Ends?

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Here's the temporary rig on the 10019
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Here's the 10207; the hole is still too high
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1 washer under the nut brings it into a more comfortable range
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If you use the Loctite blue threadlocker that actually hold the nut better then a cotter pin. Years ago when loctite was not available to consumers we used it on aircraft. I went to a seminar before we began using it and saw the tests they did. The use measured frequency and the nylon locked nuts loosened at certain frequency, then they raised the frequency till the nut broke off the head and tail of the cotter pin which was properly installed. The nut with the loctite never loosened. When we used loctite we had to clean the threads with loctite cleaner even though the bolts and nuts were new. I know that not many if any clean the surfaces correctly, me included, but I have never had an issue with loctite I have used on my cars.
 
I run into the "high hole" thing a lot. I tap the cotter pin head down into the slot. I'm too lazy at that point to go find a washer.
Yup, that's the problem: I'm sick of it.
I put some Grade 8 washers under the nuts of the 10019s to get me back on the road for now.
There's a good 1/4" of rust in the top of the tapered hole that says they're not seating correctly. I could buy a reamer for $90, but then what? Maybe it's my OCD, maybe no one had this problem, maybe there's junk on the market, but any way you slice it, I'm not satisfied. This is bullsh!t.
 
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So, a stroke of genius has struck this morning. My buddy with the ZR1 has this whiz-bang machinist dude that's been helping him on his projects. I think I'll take the 10207 Blazer ends to him, and have them rethreaded down to the 5/8-18 to fit the adjusters. I've been looking for a chart to match my measurements from the knuckles up to, and coming up short. The Moog chart has one that's close, but not quite...
Sidenote to pontiacgp: the 10017 shows as fitting squarebody 1/2 ton trucks, FYI.
 
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