2004 GMC Sierra Buildup - Hotchkis Sway Bars

In went the new McGaughy's shocks. You can also see, the old, crusty tie-rod ends that were reused. Don't worry, we're also going to replace those and the ball joints, just not on this day.
In went the new McGaughy's shocks. You can also see, the old, crusty tie-rod ends that wer
Marcel and I were now ready for the new 17⁄16-inch Hotchkis sway bar. This bar is serious and included really nice greasable bushing mounts and burly new endlinks.
Marcel and I were now ready for the new 17⁄16-inch Hotchkis sway bar. This bar is serious
As mentioned, the new Hotchkis endlinks were very stout and bolted right to the lower control arm.
As mentioned, the new Hotchkis endlinks were very stout and bolted right to the lower cont

I was now able to install the new AP Racing big brakes, which we'll cover in-depth next month.
I was now able to install the new AP Racing big brakes, which we'll cover in-depth next mo
Out back, I had cut out and installed the McGaughy's C-notch on the passenger-side, but ran out of time to handle the driver-side. Thankfully, former Sport Truck editor Mike Finnegan arrived and we quickly put him to work. First, he placed the notch onto the frame and marked the "C" with a scratch awl.
Out back, I had cut out and installed the McGaughy's C-notch on the passenger-side, but ra
With the lines marked, he drilled two large holes on each corner (these will enable a horizontal cut with the saw).
With the lines marked, he drilled two large holes on each corner (these will enable a hori

A Sawzall was then used to cut the frame away and a disc grinder cleaned up the rough edges and trimmed any excess.
A Sawzall was then used to cut the frame away and a disc grinder cleaned up the rough edge
After several test-fitments, the McGaughy's notch was held in place with two C-clamps and the bolt holes drilled.
After several test-fitments, the McGaughy's notch was held in place with two C-clamps and
Each supplied bolt was then torqued to spec and the new polyurethane bumpstop installed.

Keeping with the rear suspension install, each axle U-bolt nut was removed thanks to a breaker bar. To gain access to the driver-side leaf spring bolt, the gas tank had to be lowered down and swung over. This sounds more difficult than it is and two 15mm bolts hold the straps in place. Thankfully, we had less than a quarter of a tank of gas.
Keeping with the rear suspension install, each axle U-bolt nut was removed thanks to a bre
A 13/16-inch wrench was then used to remove the leaf spring bolts, which allowed for the leaf springs to be pulled free. The new Hotchkis 4-inch drop leaf springs were then bolted on using a 2-inch drop shackle from McGaughy's.
A 13/16-inch wrench was then used to remove the leaf spring bolts, which allowed for the l
Helping the truck really handle front to back, we ordered a rear sway bar from Hotchkis. The sway bar came complete with axle clamps, heavy-duty dog bones, and greaseable bushing mounts.
Helping the truck really handle front to back, we ordered a rear sway bar from Hotchkis. T

Step one was to loosely hang the sway bar from the axle and find the proper positioning of the dog bone mount. With the position marked, we drilled two holes in the frame and installed the mount using the supplied bolt bracket and hardware.
Step one was to loosely hang the sway bar from the axle and find the proper positioning of
The dog bones were then bolted into place using Grade-10 hardware. Thankfully, we already had the gas tank lowered on the driver-side, so we had access to the inside of the frame for the driver-side mount.
The dog bones were then bolted into place using Grade-10 hardware. Thankfully, we already
It was now time to tighten the dog bones to the sway bar using the supplied bolts.

Each axle U-bolt was then tightened, the new McGaughy's shocks installed, and the gas tank reinstalled.
Each axle U-bolt was then tightened, the new McGaughy's shocks installed, and the gas tank
Finally, after a long day of testing and wrenching, we were ready to bolt on the new wheels and tires—in this case BMF Novakanes, sized 20x9 inches and Nitto NT05 275/40R20 tires. This combo look sinister and race-ready, a combination not easily achieved for a performance truck.
Finally, after a long day of testing and wrenching, we were ready to bolt on the new wheel
With the jackstands removed and the truck on its new suspension/wheels and tires for the first time, we had our only problem—the wheels wouldn't turn. Come to find out, the McGaughy's spindles had slightly different locations for the brake caliper mounting tabs. Because of this, the AP Racing calipers were rubbing the rotor surfaces and locking up. After a failed grinding attempt in the dark, (sorry Brandan), we called a flatbed and went home bummed out.
With the jackstands removed and the truck on its new suspension/wheels and tires for the f