I bought some ace hard bushings for my classics. I went to put them in and they seem way too big for the truck. Am I tripping or anyone else noticed this? Once I put the bushings and washers on there was only like 1cm of kingpin to put my nut on and tighten it down.
Do you mean one mm of kingpin, so almost one or two threads showing?
This is what Indy trucks used to be like with the taller bushings, before they changed them down, so if you took off the kingpin nut on a new set, it was near impossible to get it back on until the bushings had compressed down some. You can still press down firmly on the kingpin and tool to push the bushings down some to then get the nut on nicely, as I used to have to do, but if it doesn't want to go on at all, see options below.
I haven't seen the hard bushings, so don't know much about them besides the height and duro, from looking at them online, but I am guessing like any bushings, you need to get the nut down on them to make them compress and work, otherwise they would be very loose.
Being hard bushings too, if things are too tight / don't work, try the stock top with the hard bottoms at first, or mix and match to see what works best.
Only other thing I usually do is cut the tops down - just take a single mm or two max from the lower part of the top bushings, as I have done on many bushings of all types, shapes, sizes, etc but that is probably not the sort of thing you want to hear with your brand new hard bushings.