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Thanks Klay, This makes sense to me and matches my expectations. I drilled out the aluminum to match the Stainless piece once it was installed. Drilling through the aluminum with the spot weld cutter is like a hot knife through butter as you mentioned. Rockers are on and look perfect.

So what does " Yea no amount of anything was going to get those bolts to all align exactly perfect, even with the bottom bolts totally loose. Drilled out a small amount of aluminum, spot weld cutter centered in the stainless hole beautifully, and rockers are installed.

So if I understand this correctly, its normal to drill some aluminum out. No amount of preload was going to fix that slight misalignment. When I said you dont, I meant you dont get the holes to align perfectly and it doesn't matter at all.

They came with the bottom bolted together. I could lift the car off the ground and it didn't change the alignment

I did preload them. I think the answer is you dont get all the holes to align perfectly, and when you drill, it makes the hole bigger in the aluminum. At least thats what it looks like based on all the aluminum flying in @Fluxor install video

How should I get the holes to align between the steel piece and the aluminum backer?

Is it possible to keep the rear plastic inner fenders with the rear aluminum corners? There is a plastic tab that sticks through the body and not sure how to make room for it.

@Kevo- is there still a plan to make replacement seat fabric? (2006 gray/black interior)

Going to try to get the rockers and corners done over a long weekend. Going to lift the roof off tomorrow and hope this all works out and only kinda looks like shit. @Fluxor can I bother you as I have questions?

What do i need to reach inside for?

Klay, Do I need to take the hardtop off to install corners? Do I need to install the rockers and corners all together at the same time? Should I wait on the fluxor rear bumper until the very end? Thanks!

This China flaring tool, obviously the same as the eastwood tool, but $66 is the cats meow. An idiot can make double flares. Blaine helping out as usual via late night emails. Brakelines going on tomorrow.

I thought these jeeps had rust???

Threw this old driveshaft in and put the savvy cable shifter in. Once i realized the ball ends of the cable shifter were removable, life was easy.

Do some research on the JJ bracket on the axle. Many don't like it or aren't using it. Reinforcing the tower for the rubber bushing may be a better choice. I don't recall what the rear axle LCA bracket looks like off the top of my head, but I dont think the skid would fit. If it did it would...

Was from 14 months ago dawg

BTW wrapping a car sucks ass and trying to do a jeep grill is extra bad. Slowing abandoning the idea.

Its on 4 wheels am im really liking the way its sitting. Big thanks to everyone, especially @hosejockey61 for all the help thus far. More to come!

Clearanced the spring perches. Running the blackmax shocks and will probably ask Mr Blaine to outboard once its running and not a disaster.

Life has been busy. Made some shitty welds to move the spring perches back, and painted. Ordered new rear calipers but ended up with ford 8.8 calipers. If anyone wants them, I can ship them to you for the cost of shipping. Brand new DFC calipers.