I figured out my problem, but have a few directions I could go.
I didn't mention in my opening statement that I'm using the MM solid rack bushings, which are for the stock k-member and all so I figured in and out. I didn't realize they require the cutting of the metal shoulder/sleeve guide (that the rack slides onto OEM style) to flush mount the rack to the kmember, essentially using the sleeve as a giant washer off the back, to only use the stock skinny bolts going through the rather small holes of the MM bushings.
The QA1 uses 5/8" bolts completely ditching that shoulder sleeve, so I realize I need OEM sized bushings with no sleeve to use their hardware.
Should I drill out my solids to 5/8 on a drill press? Is that accurate enough? They're machined pieces to start.
Option 2: I suppose is to just ditch them and get OEM replacement urethane.
Option 3: Cut the ~5/8 oem sleeves down and run the oem bolts through them and the QA1 kmember and "stock" MM bushings. I haven't tried to go out and see if the sleeves will fit through the QA1 washer tabs.
I'm kind of leaning towards just getting OEM sized urethane, which should fit and be the least amount of parts and variables.
'92 Notch prepping for WRL GP1
Previous owner - DHG Bullitt #2439
Magnaflow catback, Mac o/r H, Tri-Ax, 3.90s, 275/40/17 Nittos, [email protected]