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ARRRRRGGGHGHHH!
Got the call from the machinist today that the bushings were sized correctly and to go get the boom. Went there, and tried the pin in the holes (seemed to be the thing to do).
And.... it didn't fit.
The machinist had POUNDED the pin in with a 5# hand maul and I think he may have mushroomed the head. OK, had him turn it down so it would fit. Noted that the pin was bent a bit (5 mils or so). It would only go in from one side. OK, can do. Had some discussion on how the pin is retained. There is a slot in the pin and a tab is inserted into the slot thru a slot in the bushing/housing. Explained it to the machinist. Actually we took more than 5 min as he didn't get it for a while.
Finally tweaked the pin and bushing so it would fit nice. Mostly took out nicks he put in. OK.
Get the boom home, get it off the trailer and turned around. Ever hung a 700# 10' long freshly painted thing from an engine picker and spun it around in a crowded shop? Take my advice - don't. Certainly don't get in a hurry or the picker may go nose over. You can't see it in the pictures, but there is a 5 gal bucket full of broken gears and such on the back of the engine picker.
OK, moved the boom in, brought the box back, moved the boom into position, raised it up and got everything to align. Slid the pin in 1/2 way and it froze. Checkd and the boom was cocked down a bit. Got a wood stake and levered it up 1/16" from one side and pulled the pin in from the other side. Had to tap it the last 1/4" - not hard nor many taps.
Go to put the tab in the slot that holds the pin.......
NO SLOT CUT IN THE BUSHING.
All I can say is that it is a good thing that the machinist is 40 miles away.....
jb