Gents,
I don't often visit this forum but I have been going through this same procedure albeit slowly on my frame over the past few months. Let me relay some of my findings. Just to be clear, I am doing this with the body off the frame. Additionally, I am installing a tko600 at the same time.
* The dimensions for the whole in the disc 23/32 is a typo. I found this out the hard way, but ended up using it to some advantage in getting things lined up. The real hole size is like 7/16 if I recall correctly. Since the holes in my discs were too big, I decided to cut a square plate from 1/8 inch thick steel with the correct bolt hole size in it. By threading the bolt through the square plate, then through the disk with the larger hole, I was able to adjust the position and then tack weld the plate and disk to the crossmember..
* Getting it all lined up without the top hat bushings was difficult, because as mentioned earlier, since you are hard mounting the crossmember to the frame, you need to hard mount it at the correct pinion angle to make sure your driveline angles are correct. This means you are trying to tilt the unit and position it side to side, hold it and then weld it. If you can do all that at the same time, you are a better man than me. The trick I came up with to help me make it happen was to take an old top hat bushing (from old crossmember) and slice 2 quarter inch thick slices from it using a bandsaw. I could then put the slice of bushing in the crossmember and it would help hold the crossmember close to lined up side to side and still allow me to set the correct tilt using two hydraulic jacks (at the front and rear of differential).
* Since I am installing a tko600, I had to set my driveline angles. With the Tko 600, I found I had to significantly raise the front of the diff to get the angles correct. That leads to the next problem the VIP article does not mention. The front pinion mount for the differential which mounts the diff to the frame will no longer work due to the higher angle. For me, I ended up grinding off the bolt support plates, welding up the front hole and extending the bracket and then relocating the front hole to be where I needed it to be. I left enough room for a trimmed down mount between the bracket and the frame.
After I did the above, I decided to check clearances and we lowered the body onto the frame just to make sure it all worked. The combination of the raised diff and the angle I had to mount it at was very tight indeed. There was a slight gap left, but I decided to grind a tiny bit off the diff housing (reinforcing ridge, and only took like an eighth) to give better clearance.
I'm still in process and the above makes much more sense with pics, which I have, just not here. I'm happy to post but can't do it tonight.
Cheers.