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I'll start documenting this project even though it's in it's infancy, PA_JERO and I decided it was time for an all out crawler since we've been getting into some pretty crazy trails lately. We need something lighter with less body, originally we were going to start with a parts rig but this...

I try to be helpful!

I haven't started it yet, me and my homie are just collecting parts and getting it running nice. The goal I think is around 100" wheelbase, full hydraulic steering and body integrated armor for maximum clearance. I'll make a separate thread to keep this one on topic.

They look super cool, the one we got to build is a bright blue too. I already did a little MSPaint rendering based off UtahYota's FJ ?.

I just got a V6 Raider for this same thing, 3 link front and 4 link rear on 40's.

Yes, I've done two other ones almost the same except on coilovers. I've got probably 50k miles on mine including A LOT of really hard wheeling, I even had my axle over steering (crushed the threaded steering stop) which lead to a broken steering gear which requires a tremendous amount of force...

You should post up an info thread on your work, I'd love to see it. What size tires are those? looks like A LOT of lift.

I'd keep the non locking rear because that's the one that will be more serviceable in the future, parts are still available for the air locking axle but that will change like it did for the 92-96 Monteros. With the non locking axle you can run an aftermarket locker like ARB which has unbeatable...

I think so, the frame on the Montero is very small on the front. Not to say it isn't strong but it wasn't engineered to have it's crossmember and IFS removed then a bunch of unsprung weight added not to mention the sprung weight is now being carried at the same place the engine is mounted. Would...

Still unsure on the engine stuff but I attempted to flex it out in the driveway to check for clearances. I was only able to get full bump, I'll have to wait till it's running to measure for limit straps. Looks like I can run a full 34x10.5 tire, it's got 285/70R17's on it currently.

He was a cool dude.

Holy smokes! Yeah, looks like some wiring gremlins were installed. I'd see about getting a new engine harness from a same year donor. I'd recommend pulling it yourself if possible to avoid getting another butchered harness.

The JK axles are kinda terrible, really weak housings and they bend even with sleeving them or trussing them so best bet is to get an aftermarket JK housing for rock crawling. The JL axles are supposedly better but I haven't researched them much, I just used the JL axle because I got a deal on...

PLH in this thread posted my project threads. No death wobble at any speed or condition BUT I have had a few issues, the big one was that my knuckles were allowing too much steering angle which was great for my turning radius but caused me to break axle shafts pretty early on. I didn't know that...

The '90 I'm doing on the cheap, I haven't totaled it up yet but I've probably spent close to 2K on parts and materials and I got the front JL axle for free. I do all my own work and I still need to buy some more things but it rolls and steers at this point. I'd say if you hunt for deals on parts...

The IFS can hang with 37's but it's a lot more maintenance, you'll be doing ball joints and UCA's at least yearly (sometimes more) and replacing (bent) idler arms nearly every trip out. It's not like you'll be experiencing lots of broken parts (throttle control dictates this) but the wear will...

Pinion flanges between the 8" and 9.5" are splined differently, you have a driveshaft for an 8" and installed a 9.5" correct? You can turn down the 9.5" pinion flange to work with the stuff you have assuming you don't have a '94 SR axle, that one is odd and fits nothing I've found.

That'll about do it, I'd highly recommend getting the 3.15 transfer case gears or swapping the 4:1 T-case or better if you've got an SAS on the horizon.

I believe it was harder to swap but It was a good deal and it was like new (still has all it's paper part number stickers), I only changed directions with this truck because things kept falling in my lap. It actually wasn't a nice truck when I got it, It had been gutted and parted out. The big...

Dang, that's pretty amazing.