Suspension gurus are among the most highly sought, and paid, technicians when it comes to off-road racing. All the power in the world is useless if you cannot put it to the ground and control it. A race bike with superior suspension will destroy a race bike with superior power, riders being equal. Savvy racers on tight budgets put their money into suspension before power.
I got into doing our own bikes using Race Tech Gold Valves and valving guidelines and it paid off hugely in our racing success. I also learned how the innards in a shock are supposed to work and what needs done to tailor and tune them. I don't call myself an "expert" since I rely on the years of experience of Race Tech to guide my initial valving selections rather than my own "formula" that some guys think is necessary. I guess I'm a "cookbook chef". Why can't the aftermarket offer us truck owners such a rebuildable, tunable shock? One with external Hi and Lo Speed compression and rebound clickers like our bikes have for fine tuning to track conditions?
I like what you did with that '94, Bob. Currently, I am spending my kid's upcoming Christmas and, at this rate, college futures, on my front suspension and steering. The rear can wait, but will be addressed next year.
When I did my big Chevy K30/V30 crewcab srw suspension, all 4 leaf springs and shocks (oh so simple and the steering needed very little other than a drop pitman and quick-detach sway bar!), I opted for a simple soft-ride setup from Skyjacker, Rancho RS9000's, and firestone air bags in the rear. It is not a desert racer, or a rockcrawler. The steering and ride is SOOO silky-smooth and stable and versatile, though. It hauls any load I need levelly. It flexes and 4-wheels very well here in the midwest. It is stable and rock solid at all speeds. It does not break. It cost about $1000 back then (mid 90's) and is as sweet today as ever. I love that truck!
Long-travel air bags were not available (to my knowledge, and I looked hard) back then, so I did my own thing with custom mounts. I still don't know where you found yours?
As for the 3rd gen front springs, can you elaborate a bit on those? My '96 2500 was supposedly ordered with 3500 springs (a srw 1-ton). The fact that I have never had an issue with frontend sag, even with a 900+ pound snowplow hanging 4 feet past the frontend, or rubbing with 285-75R-16 tires (@ 33"), is proof to me that they are heavier front coils than other 2500's have. The rear has 3" wide springs with factory overloads.
I would like to fit 35" tires, but I also want to keep my COG (center of gravity) reasonable enough to carry a cabover camper. So not much lift.
You said the 3rd gen factory (3500?) front coils give 3 inches over stock on my '96? Two inches would suit me, but 3 isn't too much and it should give better coil action than spacers. Maybe I should look for some 3rd gen 3500 front coils?
It used to be that National Spring made excellent custom rear (and front) leaf packs based on your specifications for vehicle, lift desired, ride quality, load carrying, etc. for a very reasonable price. I don't know if they are still around, but I had hoped to eventually find such a setup to replace my factory boards and lift blocks.