Project: No end in sight

[Fyresq]

So a year and a half ago I decided I wanted a Jeep, so I went looking around and ended up buying a '71 FJ40 (although I knew next to nothing about them) for $2500 from a friend cause I thought it looked cool. I think I probably paid too much. Anyway, the original plans were to make it road worthy and wheel it a little. I started researching and realized that the front end was crap (coarse spline drums) the 3 speed sucked and the motor was garbage (even though it runs good). So here is the start of my build. I guess my biggest problem is that I'm pretty anal retentive and indecisive. It's going to end well I think cause I have a TBI 350, Dana 300 4:1 HD's Twinsticked, Dana 60 front, 14 bolt rear, 5.38's......but wait a minute I'm getting ahead of myself.........here's the start.
http://i219.photobucket.com/albums/cc111/bradyb4/camo.jpg
Whoops :eek: I meant
http://i219.photobucket.com/albums/cc111/bradyb4/y1.jpg

[Fyresq]

A few more........
http://i219.photobucket.com/albums/cc111/bradyb4/y4.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y3.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y2.jpg

[Fyresq]

With the help of Hollar's 4x4 it began to take shape to look like this. This is after a SOA, Shackle reversal, cut and turn, Mini truck disc outers with v6 calipers and FJ60 rotors and a 4x4 labs high steer setup with power steering conversion
http://i219.photobucket.com/albums/cc111/bradyb4/y5.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/writeup34.jpg

[jeeper89]

looks good:Big Grin:

[MR.ROCKAPE]

IT LOOKS LIKE IT WENT FROM GHETTO TO GHETTO FABULOUS!!!TRY NOT TO BE TOO INDICISIVE AS IT CAN BE VERY EXPENSIVE TO DO TWICE OR THREE TIMES!!LOOKS LIKE A GREAT START FOR SURE!!!

[xjmoser]

.........here's the start.
http://i219.photobucket.com/albums/cc111/bradyb4/camo.jpg


It looks like a good start to me too!

[MR.ROCKAPE]

It looks like a good start to me too!

X2 THOSE HEADLIGHTS KICK ASS!!!:cool:

[Sierra Valley]

Looks good. Is it a wheelable yet?

[Fyresq]

Because of my indecisiveness I have 3 sm420's, 2 700r4's, three t-cases, two dana 60's, three 14 bolt, a couple sets of gears.......and the list goes on, I just tell myself that when I decide what I want I'll already have it and can get rid of the rest

[jeeper89]

sounds like a nice parts list:eek:

[L.D.]

where did you say you live ?

[MR.ROCKAPE]

where did you say you live ?

NO KIDDING....I JUST BRING OVER A COUPLE HUNDRED FEET OF TUBE AND BUILD ANOTHER BUGGY OUTTA YOUR UNUSED PARTS!!!:Big Grin:

GOT ANY CHEVY FRONT 60s YOU WANNA SELL???

[POOR BOY]

NO KIDDING....I JUST BRING OVER A COUPLE HUNDRED FEET OF TUBE AND BUILD ANOTHER BUGGY OUTTA YOUR UNUSED PARTS!!!:Big Grin:

GOT ANY CHEVY FRONT 60s YOU WANNA SELL???

he lives out in g-ville

[Fyresq]

Still have plans to cut down the chevy 60 I have 4.5 inches and run it with a dually 14 bolt rear. Just sold my Dodge 60 front. I live in G-ville. The camo shot was the attention getter that all mediocre builds need. :Big Grin: It was just me taking a shot of the girlfriend after I bought her a camo bikini at Sportsman's. Took the top off, supposedly the first time ever and then took a little spin. I gave the rear seats away but still have the fronts with decent frames if anyone wants them
http://i219.photobucket.com/albums/cc111/bradyb4/x1.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/x2.jpg

[MR.ROCKAPE]

The camo shot was the attention getter that all mediocre builds need. :Big Grin: It was just me taking a shot of the girlfriend after I bought her a camo bikini at Sportsman's. Took the top off, supposedly the first time ever and then took a little spin.


NOW I READ THIS BEFORE I LOOKED AT THE PICS AND THOUGHT IT TOOK A CAMO BIKINI TO EVER TAKE HER FOR HER FIRST SPIN!!!:Big Grin:SORRY I GET LOST WITH BOOBIE PICS AND RIG PICS MIXED!!!:cool:

EDIT: WHERE DID THE OTHER PICS GO???:frown:

[POOR BOY]

NOW I READ THIS BEFORE I LOOKED AT THE PICS AND THOUGHT IT TOOK A CAMO BIKINI TO EVER TAKE HER FOR HER FIRST SPIN!!!:Big Grin:SORRY I GET LOST WITH BOOBIE PICS AND RIG PICS MIXED!!!:cool:

EDIT: WHERE DID THE OTHER PICS GO???:frown:

ya x2 i guess im missing out

[xjmoser]

It was just me taking a shot of the girlfriend after I bought her a camo bikini at Sportsman's. Took the top off, supposedly the first time ever and then took a little spin.

Come on we need PICS........:Big Grin:

[Fyresq]

Ha Ha.........yeah I worded that one a little wrong didn't I. Fortunately for me it wasn't the first time the top came off her but it was for my 37 year old cruiser. And then I took the CRUISER for a spin before tearing it apart some more.

[POOR BOY]

Ha Ha.........yeah I worded that one a little wrong didn't I. Fortunately for me it wasn't the first time the top came off her but it was for my 37 year old cruiser. And then I took the CRUISER for a spin before tearing it apart some more.

weres the pics man:Smile:

[Fyresq]

Decided to Whack 2" off my rocker panel since there was rust anyway. A little more body clearance won't hurt.
Before
http://i219.photobucket.com/albums/cc111/bradyb4/x5.jpg
During
http://i219.photobucket.com/albums/cc111/bradyb4/x7.jpg
After :Big Grin:
http://i219.photobucket.com/albums/cc111/bradyb4/x8.jpg

[MR.ROCKAPE]

YEAH MIGHT AS WELL CHOP IT OFF...LESS TO DENT!!!:eek:

[rusty_tlc]

Decided to Whack 2" off my rocker panel since there was rust anyway. A little more body clearance won't hurt.
Before
http://i219.photobucket.com/albums/cc111/bradyb4/x5.jpg
During
http://i219.photobucket.com/albums/cc111/bradyb4/x7.jpg
After :Big Grin:
http://i219.photobucket.com/albums/cc111/bradyb4/x8.jpg
Bolt a couple of pieces of 2X2x.125 angle on there and your good for sliders.

[Fyresq]

Well I started with the rear sill......it was pretty much completely rusted out. Lots of hacking.
http://i219.photobucket.com/albums/cc111/bradyb4/x9.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/x10.jpg

[Fyresq]

Heres what came out and all the rust with it :eek:
http://i219.photobucket.com/albums/cc111/bradyb4/x11.jpg

[Fyresq]

and braced it up........was hoping there wasn't this much rust. I was told that rust is always 10 times as bad as it appears to be.
http://i219.photobucket.com/albums/cc111/bradyb4/x14.jpg

[rusty_tlc]

and braced it up........was hoping there wasn't this much rust. I was told that rust is always 10 times as bad as it appears to be.
http://i219.photobucket.com/albums/cc111/bradyb4/x14.jpg
With 40's if you see a couple of blisters in the paint there will 100 times as much under the paint.
Your sill actually looked a little better than mine does.

There is freedom in the rust.

[Fyresq]

Well......I really wanted to cut the bottom rear corners and replace with 1/4 corner pieces but.......I have rust in everyone of my seams (I know I'll never get it all) so I decided to cut the entire rear quarters off and start new. :Smile:
http://i219.photobucket.com/albums/cc111/bradyb4/y6.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y8.jpg

[Fyresq]

Bought a new pressurized sandblaster since my gravity feed sucked and spent some time on the inner fenders and started spraying the underside with phosphoric acid.
Before
http://i219.photobucket.com/albums/cc111/bradyb4/y9.jpg
After
http://i219.photobucket.com/albums/cc111/bradyb4/y10.jpg

[rusty_tlc]

Well......I really wanted to cut the bottom rear corners and replace with 1/4 corner pieces but.......I have rust in everyone of my seams (I know I'll never get it all) so I decided to cut the entire rear quarters off and start new. :Smile:

http://i219.photobucket.com/albums/cc111/bradyb4/y8.jpg
I like it. Just skin the part between the inners and the tub rim.

[MR.ROCKAPE]

HOLY CRAP.....YOU DO KNOW THAT IF YOU LET OFF THE TRIGGER THE SAWZALL WILL STOP CUTTING???:Big Grin:

[Fyresq]

I have a plasma now :Big Grin:

[rusty_tlc]

HOLY CRAP.....YOU DO KNOW THAT IF YOU LET OFF THE TRIGGER THE SAWZALL WILL STOP CUTTING???:Big Grin:

Thats what happens when you don't stop cutting until the rust is gone on a 40.

[Connect]

Maybe It would be better to buy a replacement cab/vehicle for that thing :)

[MR.ROCKAPE]

Thats what happens when you don't stop cutting until the rust is gone on a 40.

MUST BE A LC THING......CUT 90% OF IT GONE.....ADD CHEVY AXLES/MOTOR/TRANS.....AND SOMEONE ELSES T-CASE......NOW ITS A GOOD WHEELER???:mullet:

DONT WORRY ITS ABOUT THE SAME THING FOR A JEEP TOO!!!

[jeeper89]

MUST BE A LC THING......CUT 90% OF IT GONE.....ADD CHEVY AXLES/MOTOR/TRANS.....AND SOMEONE ELSES T-CASE......NOW ITS A GOOD WHEELER???:mullet:

DONT WORRY ITS ABOUT THE SAME THING FOR A JEEP/TOYOTA TOO!!!

FIXED:Big Grin:

[Sierra Valley]

Damn, that think is on its way to being like Conol Mustards. Like the progress, less body means less crap to get hung up on.

[rusty_tlc]

If your interested this is the best pricing on after market body panels I've found.
Canada Cruisers (http://www.canadacruisers.com/product_qp.htm) they have a good reputation on ih8mud.

The only thing I was interested in was the
REAR SILL KIT (http://www.canadacruisers.com/product_sk.htm)

[Fyresq]

Thanx for the tip Rusty, I got these on sale from CCOT. Mock-up
http://i219.photobucket.com/albums/cc111/bradyb4/y13.jpg

[Fyresq]

Did some fenderwell patching. I know the welds look like crap, but it's on purpose :Big Grin: I was just trying to stitch weld so I didn't warp the metal too much. I don't have a gas torch setup and haven't done much brazing but am getting decent with my gas shielded mig and .025 wire. For holes and big gaps I use a copper backing, seems to work good.
http://i219.photobucket.com/albums/cc111/bradyb4/y12.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y11.jpg

[rusty_tlc]

Thanx for the tip Rusty, I got these on sale from CCOT. Mock-up
http://i219.photobucket.com/albums/cc111/bradyb4/y13.jpg

Looks nice:cool:
How was the fit?
Are you going to trim them up or keep them as is?

[Fyresq]

I'll have to trim them cause the rear axle is getting pushed back :Smile:

[rusty_tlc]

I'll have to trim them cause the rear axle is getting pushed back :Smile:
Is it staying leaf? If so what springs?

[Fyresq]

I've been looking for a set of 55 rears but may ending up going with 60's and redoing the mounts since I can't seem to find the 55's........or make a hybrid leaf.

[rusty_tlc]

I've been looking for a set of 55 rears but may ending up going with 60's and redoing the mounts since I can't seem to find the 55's........or make a hybrid leaf.
Yesterday I got an e-mail from a guy that is trying to part out a 55 before he moves. If your interested PM me your e-mail and I'll send it to him.

I have a set of 60 springs that will eventually live under my rig. They are much stouter than the 40 springs and a lot easier to come by. But like you mentioned it's a bit of work to redo the mounts and stuff. Proffitt's (http://www.proffittscruisers.com/index.html) has the stuff you need if you go that way. I've bought a few things from them and am very happy with the service and quality.

[Fyresq]

Well I went to put in an sm420 and 3-speed case to drive around in this summer until I tackle the v8/700r4 project and it just wasn't my day. I had to get the pilot bearing out of the crankshaft to put in a "special" bushing and it wouldn't budge. Of course the only way to get it out is to pull it. So two broken pullers, several slide hammer bits, a torch, several air hammer bits, and two messed up screwdrivers, I finally broke out the BFH and started banging away. Good thing it was hardened steel so I could break it . My forearm is toast. 1/2 hour to bust the inner race and remove bearings, another 1/2 hour busting the outer race. So dead tired and already pissed, I go to put in the cltuch disc and pressure plate and the Fing morons ordered me an 11 7/8 disc rather than the 11" I asked for . So project on hold again.......:14:
http://i219.photobucket.com/albums/cc111/bradyb4/y14.jpg

[MR.ROCKAPE]

Well I went to put in an sm420 and 3-speed case to drive around in this summer until I tackle the v8/700r4 project and it just wasn't my day. I had to get the pilot bearing out of the crankshaft to put in a "special" bushing and it wouldn't budge. Of course the only way to get it out is to pull it. So two broken pullers, several slide hammer bits, a torch, several air hammer bits, and two messed up screwdrivers, I finally broke out the BFH and started banging away. Good thing it was hardened steel so I could break it . My forearm is toast. 1/2 hour to bust the inner race and remove bearings, another 1/2 hour busting the outer race. So dead tired and already pissed, I go to put in the cltuch disc and pressure plate and the Fing morons ordered me an 11 7/8 disc rather than the 11" I asked for . So project on hold again.......:14:
http://i219.photobucket.com/albums/cc111/bradyb4/y14.jpg

I HAVE ALWAYS HAD GOOD LUCK HYDRAULIC-ING THEM OUT.....FILL PILOT BEARING HOLE WITH GREASE...TOPPED OFF!!!THEN FIND A DRIFT THAT JUST FITS IN THE HOLE(AN OLD INPUT SHAFT WORKS GOOD TOO...)AND SMACK THE TOOL WITH A HAMMER....BEARING WILL USUALLY COME RIGHT OUT!!!!SOMETIMES YOU END UP WEARING THE GREASE......:frown:

[rusty_tlc]

Well I went to put in an sm420 and 3-speed case to drive around in this summer until I tackle the v8/700r4 project and it just wasn't my day. I had to get the pilot bearing out of the crankshaft to put in a "special" bushing and it wouldn't budge. Of course the only way to get it out is to pull it. So two broken pullers, several slide hammer bits, a torch, several air hammer bits, and two messed up screwdrivers, I finally broke out the BFH and started banging away. Good thing it was hardened steel so I could break it . My forearm is toast. 1/2 hour to bust the inner race and remove bearings, another 1/2 hour busting the outer race. So dead tired and already pissed, I go to put in the cltuch disc and pressure plate and the Fing morons ordered me an 11 7/8 disc rather than the 11" I asked for . So project on hold again.......:14:
<snip>
That sucks. How long before you get a new clutch?
BTW I have a slick trick for installing the t-case and tranny as a unit. It works great, I've removed and replaced my tranny/tcase/tcase a couple of times solo.
http://img.photobucket.com/albums/v711/rusty_tlc/build%20up/Hoist.jpg
http://img.photobucket.com/albums/v711/rusty_tlc/build%20up/In_place.jpg

[Fyresq]

Well........it's been a long last month. The majority of my time has been spent putting TBI in the girlfriends 81 CJ7, so that left me little time to work on my own rig but here's some updates. Was tack welding like crazy to keep the heat down.
http://i219.photobucket.com/albums/cc111/bradyb4/y18.jpg
Had to leave the old filler neck on cause it's a rarer year and they usually come with a square hole for the filler rather than the square bottom half round top
http://i219.photobucket.com/albums/cc111/bradyb4/y22.jpg

[Fyresq]

Here's some shameless shots of the sbc tbi 350 and 700r4 that will find their way into the rig in the future
http://i219.photobucket.com/albums/cc111/bradyb4/y24.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y25.jpg

[Fyresq]

A few months ago I ordered up a cage kit from MetalTech and it's been sitting. I started part of it, here's a few shots. Last year I don't think I would have been comfortable welding this (safety wise) but I've been practicing my a$$ off and went in and took my my first AMS structural cert just for the fun of it and figure that if I'm certified to weld unlimited thickness steel I should be ok with this. My cert was for horizontal stick but I'd like to try for my MIG and then TIG as time allows.
http://i219.photobucket.com/albums/cc111/bradyb4/y29.jpg

[Fyresq]

I got bored today and decided to figure out a way to put the top on by myself to check clearances on the hardtop. I had to pull the valve stems to lower the cruiser enough cause my 'picker was maxed
http://i219.photobucket.com/albums/cc111/bradyb4/y30.jpg

[Fyresq]

Being a Nevada boy, it bummed me out when I had to take out my gun racks because they were hitting :gapteeth:
http://i219.photobucket.com/albums/cc111/bradyb4/y28.jpg

[Fyresq]

.......couple more shots. I still need to add some more tubing to the rear overhead and maybe sides and then I'll start fabbing the frame tie-ins
http://i219.photobucket.com/albums/cc111/bradyb4/y27.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/y31.jpg

[Fyresq]

It's been a while since I posted to this buildup thread but I have indeed been working on it. And starting it back up will give me a little motivation. So to continue the saga......I went ahead and got this setup with the idea that I'd wheel it this last summer and then continue building in the winter
http://i219.photobucket.com/albums/cc111/bradyb4/adapter2.jpg
It was an sm420 to LC 3 speed t-case with an advanced adapter. Like a moron I trusted the guy I bought it from when he said it ran great and was just pulled

[Fyresq]

...until I popped the cover and it looked like this....
http://i219.photobucket.com/albums/cc111/bradyb4/y15.jpg
So I sold the adapter, gave the t-case to poorboy, and scrapped the tranny gears. I still have the case, top cover, and stick if someone needs it

[Fyresq]

So now I'm thinking that I might as well just do the v8 and tranny that I want. And in the meantime I bought some 37" MTR's and slapped those on. That's when the future wife comes out to the garage and says "it looks tall and skinny" :maddance: GDMT she was right. My eye travels to the corner of the shop to the dana 60, 14 bolt, and 5.38 gears and I say to myself "Self.......why don't you just build it the way you want it the first time?" So out comes the tranny, t-case, 1F motor, and the axles I had just built. What it really came down to was this: I still had to buy Long axles to keep from breaking with the 37's, had to buy gears, and had to buy lockers. With the 1 tons sitting there with gears already I figured it would almost be a wash.....and why do it twice...?
I sold the t-case to poorboypulling, gave the motor away, and sold the axles to Orangefj45 (Georg) from Stockton

[Fyresq]

I then decided that full width axles on the cruiser wasn't for me so I took my axle down to WFO in Auburn and they cut down the longside tube on the front 60 to 64.5" WMS to match my stock spring width and resplined my longside axle to match. While they had it apart I had them put a detroit in with the 5.38's and slap on some of their highsteer arms with a knuckle rebuild. For whatever reason, I failed to take a picture of this.
For the 14 bolt I traded my hubs for dually hubs to make the rear 63" WMS and put in the detroit and gears at home. I then shaved it to a 13 bolt :D and I think I have more clearance than my front 60
I still have to do the disc conversion on the 14 bolt and finish the front outers
Here's a shot of the axle respline
http://i219.photobucket.com/albums/cc111/bradyb4/z13-1.jpg

[Fyresq]

Since I didn't have enough time on my hands I bought a CJ7 to cruise and wheel in......until I changed the axles to widetracks with lockers F&R, put on steel braided lines, had the tranny rebuilt, redid the exhaust/intake manifold, converted it to Howell TBI, and just replaced the D20 with a D300 4:1. :D It's for sale now cause it was for the wife and she doesn't drive it....and I have the landcruiser to work on. Until it sells, I'll just wheel it a little :smokin: I originally wanted a jeep but after working on both of them, the FJ40 is definately more stout and funner to work on.
http://i219.photobucket.com/albums/cc111/bradyb4/jeepafter.jpg

[Fyresq]

So I was putting my shafts for my front 60 together the other day and as luck would have it, I couldn't get a u-joint into one of the C's enough to get the clip on.....so I put it in the 20 ton press and proceeded to blow out the u-joint cap trying to squeeze out enough room to get the clip on :maddance: there's another $50 u-joint :mad: So I got another u-joint cause you can't just buy caps and tried to put it in again....a little more gently this time and again I couldn't get enough room. So I broke out the calipers and realized the C was bent slightly inward (maybe it got dropped :frown:)? So I broke out the BFH and didn't even move it. So I waited until I was at work today and decided to do a little "training" with the jaws of life and spread it just enough to get the clips in
http://i219.photobucket.com/albums/cc111/bradyb4/z13-2.jpg
60,000# jaws of life spreader - 1 , Dana 60 axle shaft - 0 :D

[Fyresq]

Back a few months......When I got my 60 front back from WFO and went to mount it up the pinion was almost negative and my castor was so bad my hi steer wouldn't go above my springs
http://i219.photobucket.com/albums/cc111/bradyb4/x17.jpg
I was bummed cause I had just spent time and money doing the shackle reversal and then cut down the front 60 to match the spring width since I had just messed with the new spring and shackle hangers and now I get to do it again. :bang: With the landcruiser axle this was an easy fix because I could adjust my pinion angle and caster to whatever I wanted by rewelding the spring perches and cut and turn the outers which I set at 13deg and +5 respectively. The problem with the dana 60 is that while you could technically rotate the outer c's to change caster, the 60 axle has a cast spring perch on the passenger side diff and you would have to do some major grinding and retapping to get it to work (plus you would pretty much destroy the housing for any other use).

[Fyresq]

Here's a shot of the rear shackle hanger.....it just hangs down too far (causing a little more lift than I really want) and makes the pinion angle suck
http://i219.photobucket.com/albums/cc111/bradyb4/x16.jpg

[Fyresq]

So my first change was to recess the spring hanger into the frame rather than underneath it and, while it seems simple in the pictures, took almost an entire day to cut off the old hangers, drill the big holes thru both sides, grind flat, cut and weld inner frame plates, make double sure the inner dom tubes were straight, mock it up, and then burn them in. Thank the lord for plasma cutters :D Doing this gave the front a stock spring hanger height or maybe slightly less which is a two inch drop from what it was. It should match the rear nicely since I'm putting in longer Fj55 springs and keeping the shackle hangers the same with 6" shackles which will be about a 45deg plus angle on those and give me a near stock ride height in the rear as well
http://i219.photobucket.com/albums/cc111/bradyb4/x18.jpg

[Fyresq]

The shackle hanger change and some 8 degree steel shims (doubled) gave me a much better pinion angle (10-11deg) and a postive 2 caster and now looks like this
http://i219.photobucket.com/albums/cc111/bradyb4/x19.jpg

[Fyresq]

Got the FJ55 rear springs mounted, put new bearings, races, seals, rotors, calipers and did a mock up mount of the axle today
http://i219.photobucket.com/albums/cc111/bradyb4/L3.jpg

[Fyresq]

Got the rest of the front 60 outers built up with 35 spline stubs, new hub lockouts seals, races, bearings, rotors, studs, etc., etc.
http://i219.photobucket.com/albums/cc111/bradyb4/L8.jpg

[Fyresq]

I also installed these outer seals made by Mad Mfg. After having toyota junk for so long I couldn't believe that there was no seal (besides the inner seal at the diff) to keep water, mud, and junk out of the axle tube
http://i219.photobucket.com/albums/cc111/bradyb4/L4.jpg

[Fyresq]

Here's a shot of what a dana 60 30 spline stub looks like compared to a d44 19 spline (stolen from billavista)
http://i219.photobucket.com/albums/cc111/bradyb4/image003_small.jpg
and what the difference is between the dana 60 30 spline and 35 spline :D
http://i219.photobucket.com/albums/cc111/bradyb4/image005_small.jpg

[Fyresq]

Here's how she sits now
http://i219.photobucket.com/albums/cc111/bradyb4/L9.jpg

[Fyresq]

To address a weakness with the dana 60 front, I decided to tap a third stud in the cast spring perch since the two stock bolts are notorious for breaking or stripping under heavy use. For those that don't know, the Dana 60 has a cast spring perch (in my case on the passenger side - GM). Incidentally this is the easiest way to determine if a front axle is a dana 60 - it will only have 3 u bolts (stock) vs. toy axles, D44's, D30's. etc. which have 4 u-bolts. It always seems to impress people when you take a quick look and say - nope that isn't a dana 60 :D This is what the cast perch looks like:
http://i219.photobucket.com/albums/cc111/bradyb4/L14.jpg

[Fyresq]

normally the top "u-bolt" plate looks like this in stock form. Because it is so thick it's a pain to tap a third stud so I got a custom one from Ruffstuffspecialties.com with the third hole already drilled.
http://i219.photobucket.com/albums/cc111/bradyb4/L12.jpg
new custom one with third hole
http://i219.photobucket.com/albums/cc111/bradyb4/L16.jpg

[Fyresq]

Here's the difference between the D44 stud that I'm using which is fine thread 9/16's vs. the coarse thread D60 stud used in the other two holes. GM (don't know about the others) uses bolts rather than studs in stock form so the studs already make the setup a little more stout let alone with the third stud tapped in....
http://i219.photobucket.com/albums/cc111/bradyb4/L10.jpg
And a picture of the 3rd middle hole tapped
http://i219.photobucket.com/albums/cc111/bradyb4/L15.jpg

[Fyresq]

And the finish......still have to cut down the studs a little
http://i219.photobucket.com/albums/cc111/bradyb4/L11.jpg

[Fyresq]

I have just been cleaning a few things up lately....anxiously waiting for my tranny to get done so I can start the drivetrain mockup. Cleaned the firewall up:
http://i219.photobucket.com/albums/cc111/bradyb4/z14-1.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/z15.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/z18.jpg

[Fyresq]

So it's official.......after much debate and going back and forth between my three personalities.....I picked up a set of brand new 40" mt/r's on 32 bolt Allied beadlocks, brand new for about half the price. I wasn't sure if I wanted to go this big but I couldn't pass the deal up. And what are 1 tons for right?
http://i219.photobucket.com/albums/cc111/bradyb4/z19.jpg

[Fyresq]

The dirt on 'em is from driving thru Tahoe in the slush with them in my pickup bed. Here is what they look like next to my CJ with a 4" lift and 33's:D
http://i219.photobucket.com/albums/cc111/bradyb4/z20.jpg

[Fyresq]

After a little snafu with a wrong backing plate, I'm almost done with the 14 bolt disco conversion
http://i219.photobucket.com/albums/cc111/bradyb4/z23.jpg

[Fyresq]

Here's what the tires look like on the rig.......I have a lot of fendertrimming to do....I was thinkin of doing a set of tube flares for the rear and have no idea what I want to do on the front. The front ended up being 81.5" outside to outside with 4" backspacing and the 4.5" dana 60 cutdown. My goal was to be able to make tighter trails like Barrett Lake on the Rubicon. Overall I am happy with the stance but may add 3/4" spacers to the rear axle to get it even with the front.
http://i219.photobucket.com/albums/cc111/bradyb4/z21.jpg
http://i219.photobucket.com/albums/cc111/bradyb4/z22.jpg