Wondering if you have to have front end apart to weld on gussets on a D30

 

No, removing your wheels makes things easier though.

 

Dont have to remove bearings

 

Nope, but some recommend removing ball joints so they do not melt (factory are plastic inside).

If you weld small amounts and allow things to cool off, you'll be OK.

 

I had to lift the spring up a bit with mine to get the gussets in jack stands on the frame take tires off and lower the axle down I did mine with ball joints in weld about 1/4 inch when close to ball joint then put a wet rag on ball joint for a bit and repeat.

 

Same here, ran short beads, lots of damp rags wrapped around C's/ball joints in between welds.

 

Good info, I was wanting to do mine but didn't want to remove everything

 

Done many of these,a helper is needed to make things go faster.Prep work is key,removal of paint is important,pre fit the gusset,after fitting the gusset tack in place and have fun

 

Do the gussets come with good instruction for position and weld locations?

 

Depends which ones you get. I got the EVO G2 and a lot of people seem to like them. Extremely straighforward, they seem to sit right in place when you get them in position, but there are a couple of pictures that show you also. Welding locations are pretty obvious and simple also.