Hi Mike,
I purchased a set of repro pivot bolts from RFJP and checked these after your comments. These are all .5625 inch (9/16 inch) and match the originals I had for length and with the slightly deeper castellated hex nut. I also had a few odd new pivot bolts that came with some other parts, and these were .550 inch, so thanks for the tip.
Spent yesterday afternoon assembling the gearbox after the arrival of a second T84 small parts kit (the first kit is still AWOL!). Once it is mated with the yet-to-be assembled transfer case, I'll paint the whole assembly with the early US Army olive drab colour supplied by Rapco. Also have the axle housings back and have primed and painted them, and fitted a new steering bell crank pivot pin and bearings.
The next few days will be office - the proof copy of my next book arrived from the publisher this morning, so finding and getting the bugs out of it will be the focus - there are always a few bugs that creep in during the transfer from Word to the publisher's layout program, and during the layout process. But overall, it's looking great!
Chassis is at the sandblaster and should be ready to collect in a week or so. I discovered that the chassis fits neatly inside the Chev Suburban with only about 18 inches beyond the tailgate, so makes getting it to and from the sandblaster much easier than having to go and get the trailer from storage. Also dropped the starter and generator into the auto electrician for rebuild: I could have just purchased change-overs from any number of jeep parts suppliers, but like to use local suppliers whenever possible.
Mike