Finished lifting my 4 door Sidekick. The 1.5" spacer up front lifts it quite a bit.  I'm wondering whether the springs will settle in and subside after a bit? I took it over every speedbump I could find before taking it to the shop for alignment. 

I took it to align it but the camber is still way off, even with one set of these camber bolts (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=230608841862&viewitem=&sspagename=STRK%3AMEWNX%3AIT#ht_3393wt_939)

Looks like I might need to notch the struts out. Any suggestions on how to go about that? Torch? Die grinder?

use a die grinder. much more precise. also install washers on either side so when the camber is set you can tack weld the washer to the strutto keep it from shifting.

Did you put the camber bolts into the top hole?

I don't think I would loose any sleep over the bolt diameter. there's engineering,testing and lawsuit prevention that goes into any reputable suspension components. you take in a couple camber bolts to a alignment shop they will probably act as they have seen them before, but they look under your rig and see you have "home brew" alignment that involved a grinder,welder and maybe a Pulaski on a strut they might have some conviction about working on your rig.

Did you put the camber bolts into the top hole?

Yeah. Top hole..  And the camber is way off. Reminds me of the rear camber on a an early VW bug when you lifted it. I'm gonna go look at it this afternoon and make sure all the springs are in their buckets, etc.

This just came came to mind. When I removed the bolts for the strut plates, I just pounded them out and then drilled the hole out to 3/8". Perhaps that might have distorted the plates a bit...  I don't think it could have had that significant effect though, if any.

You can cut a liitle off the insinde of the knuckle where it hits the strut and allow it to move in more. If its touching already. Funny though, I put 2"  springs in mine and the camber bolts worked fine

those camber bolts allow a remarkable amount of adjustment.
mabe jack one wheel off the ground by the a-arm, pull the wheel, loosen the strut bolts.
you should be able to crank the adjustment back and forth and see whats going on.
i have pucks and camber bolts.
you can eyeball camber pretty close, and the toe will have changed a lot.
should be able to set everything close enough to know it will work before seeing the align.guy.

mabe the locating tab isn't in right?

Well, I spent a good bit of time on the new GR2 struts with the die grinder, then ground off some of the material off the inside of my knuckles. Now there is plenty of room for adjustment. Will take it in on Tues.

I am really surprised at how much those 1.5" spacers lift the front up. I can now see why folks are so concerned about cv joint angles.  I would not want to stress them any more.