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Since I already had an extra 6 inches of shock droop I decided to get some Revolvers to use that droop.  Below are some pictures during and after the installation.  Click the pics for a larger version.

Scroll down to the second section to see the Revolver repair pictures

Here the Revolver is completely collapsed and there's a ruler showing 4.75"
Here the Revolver is stretched out and measuring about 11 inches
Stretched out, no measurement
Compared to the shackles I replaced.  The Revolvers are about 3/4" longer when they are compressed.  That will net a 3/8" 'spring lift'.
This is the shackle the way it sits with the full weight of the Jeep.
Here's both rear shackles fully drooped.
This ruler is showing about 16" to the center of the axle with the springs fully drooped and the Revolvers collapsed.
Here the axle is at full droop with the Revolvers stretched.  Ruler is reading about 13".  That nets an addition 3 inches of full droop provided by the Revolvers.  When the axle is articulating, that number can be just about tripled due to the flex allowed in the shackle itself.
I had to modify the exhaust tip because the lower shackle bolt would hang on the edge of the opening.  A simple re-adjustment with some channel lock pliers did the trick.
This picture was brightened a whole lot so the quality suffers.  Here the drive up ramps couldn't stretch the suspension as much as I would have liked.  Hopefully I'll be able to update this and the next picture to fully show the benefits to these shackles.  If you look closely, you can see the way the shackle allows the spring to twist further lessening suspension bind.
Here you can see the shackle has not opened all the way.

Revolver Repair 
(September 12, 2002)

For a while now I've been noticing that the Revolvers are not as tall as they were new.  The plastic "saddle" part of the Revolvers have collapse and cracked causing the end of the leaf spring to hit the bottom bumper bolt.  When I was on the Dusy trail over Labor Day this year, I met a fellow names Derek.  He owns a plastics manufacturing business in Victorville (not far from my home town, Temecula).  Since I stopped and helped some friends of his repair a busted shackle hanger on a CJ-7, he volunteered to make some new saddles for me out of various materials.  I got the parts drawn up on a Monday, and Thursday I had my parts.  Five different materials.  Nylon 6/6, Black Nylon, ST801, HDPE and UHMW.  I don't know much about these materials but Derek suggested I start with the Black Nylon so that's what I did.  Check out the pictures below

In this picture, the Jeep is articulated on my homemade ramps.  The front left and rear right tires are compressed.  The stock saddle is in place.  You can see how the leaf spring is almost touching the frame.  Compared to the picture at the very top of this page, it's quite different than new.
Here's a view from the back.  This is really to show how much the Revolvers let the suspension flex.  Each of the ramps are 25" tall and the tires have street pressure.
Now the Jeep is articulated the opposite direction.  Front right and rear left are compressed.  The passenger side revolver is opened up and I've installed the Black Nylon saddle.  Unfortunately, I fudged a dimension and made them the exact size of the failed parts.  Whoops.  I installed a 3/16" piece of flat material to accommodate.
Another shot from the rear.
Here's the same shot as the the one at the top of this table, but with the new saddle (with spacer) installed.  See how much more clearance there is between the leaf spring and frame?  That's how it should be.
These are the stock saddles.  I heard that Teraflex makes the saddles out of Delrin.  Derek told me that Delrin doesn't have the UV protection that other materials have and that over time, Delrin becomes brittle in sunlight. 

Thank you Derek!

Product Systems Engineering
Victorville, CA
(760) 246-7000