Metalcloak posted photos on another forum showing their trackbar on a TJ with the bump stops and springs removed and the axle jacked up all the way to simulate more than full flex. Theirs did not contact the tie rod or differential cover. It was tight, but didn't contact.
Any chance you can find these pics?
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I might be needing to do this as well. I have a 2" lift, Dana44 with a 1/4" bent steel diff cover (previous owner put on) and a JKS tb that is hitting when I go over speed bumps, and other bumps, potholes. I took it to an alignment guru and asked him to dial the front axle back. He said he adjusted it back as far as he can and I still hit but further out on the cover.When I tested it on a trail nothing touched. The clearance was really good. I'll get a photo of it this weekend.
He recommended I go back to the stock cover and I should be ok. I took some measurements of what I have and what the Dana cover is and it will definitely be close. If it doesn't work I will need to try the MC tb. I've read on multiple sites where they are the only track bar that doesn't have clearance issues on the TJs with lifts under 3".
The Dana44 cover is 2.85" tall and the one I have is 3.25".