Time for an update...
Started messing around with the transfer case and found out why the levers weren't working - they weren't hooked up. The previous owner put a drop kit on it and apparently didn't know how to install it. I'm at a loss trying to figure it out myself, it doesn't make sense. Seriously, as an engineering major, it doesn't make sense. So I'm going to use a rod through the original tcase opening to push and pull the lever when engaging 4wd. Oh, and 4wd low works gooooood :D First time with 4lo in the TJ, I'm excited to get a couple spares and start wheeling.
Onto the future plans...
Picked up a '91 FJ80 front axle. 4.10 gears, 63.5" WMS, Hi pinion 8" third member, beefy everything. These are bigger versions of the regular Toyota mini truck axles. They're wider and bigger in all the right places. If I manage to explode the ring and pinions, I'll make a hybrid 80/9.5 axle using a FJ62 center chunk or go to a Dana 60. I think it will be a while before I get to big enough tires to blow apart these things.
I'm planning to run a Dana 300 with cable shifters, twin sticked, coming through the stock Tcase lever location with as little modification as possible. There's a good chance I'll have to have a 1" body lift or make some cuts to the sheetmetal but we'll cross that road when it comes. I know for sure I'll have to reroute my exhaust, get a new rear driveshaft (going with a Toy CV with flange) and get my front driveshaft shortened (possibly not) with a flange adapter. I'd rather keep my front shaft the same length so I can sell it for all TJ owners if I stretch the front. I want to get 2" out of the front and the rest out of the rear to make it 100" wheelbase when I finally longarm this rig.
Plans for the rear are one of three options: Zuk 12 bolt rear (cheap but random and doesn't match the front), Tacoma rear, or full float FJ80 rear. The 80 rears are rare and can be expensive. The Taco rears are versatile and plentiful. The 2wd V6 axle shafts are 5 x 4.5 Jeep pattern so I could run those in the back with the HP30 front until I swap in the new front. Then I swap in 4x4 shafts and I'm good to go. Leads me to my next point, which is room to grow. Picked these up for cheap. 37x12.50x17 MTRs at 50%
Started on a stubby front bumper that doesn't increase my approach angle. It's merely for protection and deflection purposes, not a permanent solution. It's the first time I've welded something significant with this $100 Lincoln I found on craigslist. It worked pretty good, used 6011 rod and got some good arcs. I'm also using this time to get my welding skills back since I haven't used them in 5 years.
I'll let the pics speak for themselves mostly. If you have any questions, just ask.
regular stock, 1/8" thick I think. I got it for $5 so whatever
Jig
design
Drill holes, make sure they're square
Drill out for bolts
