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So Ive got this JCR 1-ton set up taking up room in my garage and I'm wondering if there is a better solution then reaming out the knuckle to fit 1-ton TRE's. There isn't much beef there and I think it might make the knuckle the weak link.
if it were a problem, so many people wouldn't do it. all you're really doing is reversing the taper. it makes the skinny end of the 1 ton the same size as the thick end of the stock. a TRE or your tie rod or something will bend/break way before a knuckle.