As to whether the kingpin to axle fit is right...I wouldn't take it anywhere unless the king pin jammed as you tried to fit it, by itself, into the axle. Just make sure there are no burrs on it, and it should slide into the axle bore and locate with it's retaining pin notch.
A 'mechanic' here (Atwater, the home of the unlearned) reamed one of my spindles for me on his Sunnen wrist pin hone. I told him the measurement, but "he knew better"... honed the bushings out to .003" clearance. I didn't let him do the second one. (Hone them to .003" and they are the same as Worn Out! With the wheel and tire on it, it multiplies the 'play' at the circumference...shimmy city!) I was lucky to find an old Ford source with king pin bushings and bearings sold separately, so I ordered a shitload of bushings. I have an early Ford in-line reamer, but I just wanted 'em done quick. MY BAD...Live and learn. Just 'cuz somebody has a Maserati doesn't make him a precision driver...
That will make things go together, but it doesn't align the two bushing holes with each other, or make the holes straight and round. Either reaming with the right kind of reamer, or honing both bushings simultaneously, can do that.
Sound like you want to take off more matieral than nessasary just to make it "aligned". It should fit tight in the axle, it gets locked in. It'll all get "broken in" just like a new engine, except the TIGHT king pin that gets locked into the axle.
The bushings are normally undersized intentionally to allow finishing. Even if they aren't, I want to take off any interference without removing material that shouldn't be removed. That's what you are doing. If you are happy with that method, it does allow the pins to be inserted, and It's not a safety issue. If that's good enough for you. it's fine with me. I posted what I did for the benefit of anyone who might not understated the shortcomings of doing it your way. Feel free to consider or disregard as you wish.
I think your right. And I really am learning something from you, really. I think Im right too. Im really just sharing my experiance & my theory. I love doing things myself & in the backyard & it works most of the time, & sometimes it's not pretty, but like you said, "It works for me". Everyone on the HAMB is right, some might be wrong, I'm probally wrong, but everyone here should be concidered & heard. It all R&D. And the HAMB is the BEST R&D around!!!
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