Hi Mate,
I've done pretty much what you want to do and I'm afraid you are short on things on your list
Just the rear bags would not be enough, I take it you would be buying the front as well?
The longer shocks by terrafirma work quite well, I would opt for the adjustables.
bump stops on a P38 are clamped into place, not bolted. You could just make a filler plate on the axle pad to fix that problem, no need for other bump stops but do read on below!
rsw kit, nice but I would shell out for something that can also do other things with the BECM and such, like a faultmate extreme or whatever. Sooner or later you will need it
Regarding the tom woods, I have those and they are pretty much overkill. The angles are not to bad since the lift is only mild but I can't hurt to have them
Your questions in order:
1. The ride height sensors can not handle the lift, the front can be relocated with a small plate, the rear needs to be extended or you will snap them off.
2. I did not need to trim anything, having said that, the mudflaps in the front no longer fit and I have put a spacer in the front arms to push the wheels slightly forward.
3. I would think that pressurized air would do the trick
4. In the rear, yes. Geometry tells us that you would get more travel however I fail to see how you would like to take advantage of that since you get the extra length anyway. (only the shock limits downwards travel so a longer shock automatically means that the axle drops further extending the bags quite far, read on below)
5. I can think of a few things...
The problem, that I guess you will have come across, is that the bag's can extend quite a bit but the angle between the top and bottom half of the bag's becomes quite large. You have a chance of popping the bags and all sorts of trouble. In the front this is less of an issue. The problem in the front is that the bags are somewhat bigger and they bulge outwards quite a bit more and start chafing which can cause trouble. Since you suggested increasing the bump stops I take it you are not going for a lift kit. The former hard range kit is made by someone on this forum and I highly recommend going that route. You can build it all yourself but that kit contains most of what you need, except the longer brake lines. My only problem with the kit has been that it has effectively lifted the car instead of increased the wheel travel. That is to say, my wheel travel has certainly increased but some of the gains have been negated by the lift kit which effectively places spacers front and back between the bags. (and hence are no longer part of the longer travel)
Having said that, I do enjoy my setup immensely; the gen III bags are non-linear and provide a stiffer ride at the low (highway) setting, this is also one of the reasons why I would recommend buying the TF adjustables. The standard ones are pretty firm and that's all nice and well if you are planning to build a streetracer but during off roading you can set the adjustables a bit softer.
Regarding reprogramming the heights: you are limited in what the EAS accepts as lower and upper values per setting. Unfortunately the settings are not completely free. 1" is certainly doable in low, crawl can't really be adjusted much (for me it means: bumpstops) 2" in high is also fairly easily attainable but both only with the modified sensor arms (part of the kit I just described) I have found my car to ride really well and I am pretty much at GVM when fully loaded. Settings the TF's to 4 on highway mode one would almost think it's a sportscar My highway setting is rather low though since I do hit the front bump stops occasionally with larger potholes in the road but only slightly. The fact that the bump stops in the kit are not made of rubber but polyurethane makes you feel it a lot better as well (it's much more of a hard stop)
I can also highly recommend buying a polyurethane bushing kit and replace all those old rubber bushings, it'll stiffen up the car even more. The larger wheels have made the car a bit more sluggish but I am not bothered by it. I did not opt for a different diff ratio but I would consider it if I would do something like this again. The auto box solves most of the problems though Also, the larger wheels do put more strain on the other components so when you go tackle tougher terrain I suggest upgrading the half shafts and CV's with RCV ones.
Lastly I would suggest that the valve block will need a rebuild and possibly the compressor as well, the rubbers will most likely have perished. Also check the air dryer. If it's worth doing, it's worth doing well!
Cheers,
-P
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