Bear80

Well 1/8" did this: http://www.yotatech.com/showthread.php?t=98753

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1986 Truck - Monster IFS

1997 FZJ80 - Locked, Lifted, Ready
Range Rover Recovery Vehicle

AH64ID

Going off of memory and the steering you have rancho upper arms right? Those in them selves are effectivally a BJ spacer, as far as realtion of tbar setting to hub location... so with the BJ spacers and rancho arms you had waay more droop than either was designed for, as well as the CV's you had... I would guess the hopping hurt more than the 1/8". but thats just from reading your info, and the average CV break... which happens to people when hopping on stock suspension...

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-John
'05 Dodge 3500 SRW 4x4 SLT 5.9 Cummins QC LB NV5600
2003 SR5 4Runner, V6 4WD. 1" cornfed lift
Previous Toyota's '92 Red Truck NALA

Speed doesn't kill, its the sudden stop that hurts.

Bear80

Acutally becuase of the angled desing of the Rancho arms, the t-bars have to be cranked in quite a bit of pre-load, so you cant really look at them as a spacer in relation to hub location. Infact the sapcers are needed with stock t-bars cranked to the max to get me bearly 1" over stock. And even then the way the arms twist the t-bars render them too soft for street use. Anyway, I know a lot of people disagree with what I'm doing but it keeps me busy with a project that I can feel like I'm some what doing some fab work on without doing real fab work, achieve 12" of wheel travel without wideing the track and compaired to other TC kits and such, dirt cheap!

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1986 Truck - Monster IFS

1997 FZJ80 - Locked, Lifted, Ready
Range Rover Recovery Vehicle

AH64ID

What torsion bars are you running? When I had the POS rancho my stockers gave about 1" lift, looked really funny with 3.5" of rear lift.... So I put 26mm Sway-a-ways in, got the 3" needed with barely cranking them.... but man I hated that freakin lift.... yeah espically the way it treats torsion bars, but the HD ones worked as good as they could, given the quality of the lift...

I am not trying to knock your setup, i just think there are several factors that lead to the breakage, not just the 1/8" over on the BJ spacers... but certaily a contributing factor...

__________________
-John
'05 Dodge 3500 SRW 4x4 SLT 5.9 Cummins QC LB NV5600
2003 SR5 4Runner, V6 4WD. 1" cornfed lift
Previous Toyota's '92 Red Truck NALA

Speed doesn't kill, its the sudden stop that hurts.