Yeah, the frame side TB mount was tacked on, cut off, tacked again, cut off and butchered, then tacked a 3rd time. I did not do what you said about making the bar first, that's good to know... now...
If the tie rod hits the bottom of the pitman arm, something is wrong. I set this stuff up all the time and do my very best to keep that from happening.
Any guesses as to what it could be? I have the drag link TRE on top on both the knuckle & the pitman, I have the tie on top of the knuckles.
The durango steering box is in the OEM location, I checked the WJ arm a few times, the first time I put it on, the splines weren't modified enough, it was binding up. I was able to get it another 1/2" or so onto the box. It's up nice and tight now.
The only thing I can say is, the amount of bumpstop to clear 35s on stock fenders, clear the track bar to the frame, and clear the tie rod to the pitman arm is the same, so it seems like that's the "right" amount.
That's 4" of uptravel...
Another though. Do your setups have the tie rod squeeze behind the arm? I have the offset TREs for the tie rod, maybe that forward movement, combined with the axle being moved slightly forward is what hosed me.