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Who says you HAVE to carry a spare? OBA, tube, plugs, tractor patches, etc. Most people aren't going to be content with the size of a normal jeep, I get that, specifically in any kind of expo setting of use. For me, I have traveled ALL over the place in my little old flat fender, something the...

On your Edelbrock carb. You might want to look at blocking off the crossover fuel bowl passage with it in that orientation. That can help immensely with the performance of that unit off highway....and I imagine even on-road with it rotated 90 degrees. There are other tricks you can do too if you...

Yup, cost is going to add up FAST. Dana 60 stuff is definitely bigger. I would try and get a realistic expected weight. I commonly see TJ/YJ sized jeeps that are pushing 5-6K fully loaded. I think final vehicle weight is often underestimated or overlooked. I think D44 stuff starts to get...

37s can be a good compromise in size/weight. D44 based axles have come a long ways, but the weak link is still the axle joint. You can do something like RCV's or CTM joints or whatever, but its still a 297/760 joint. For some combinations its just fine, for others its marginal. It depends a lot...

One of the better overall combo's in my opinion, Run a beefy TH400 auto with a manual valve body and gear the axles for the highway speeds you want ( taller gearing than normal ). Then run a multi-speed transfer case to give you a good middle range for the sand/desert/mud and some deeper gearing...

You could always do a hydraulic/mechanical automatic trans, you could even go as far as using a manual valve body. For HARD off road use I think a manual needs deeper gears than are easy to fit in most chassis. It is really nice to have a decent middle gearing range for desert/sand/mud stuff...

Yup, That is why I went with a common boring jeep body as a base. If you think about it too much you just never get anywhere. You can build anything to do this.....its building it cost and time efficiently that is the real challenge! Rebuilding an existing vehicle could be just as much work, or...

The CJ project I have been working on I showed earlier is just the SKINS of a CJ7/YJ. It isn't based off using a tub. The entire frame and inside is custom. You could do something similar with a scout, but finding replacement scout parts is going to be tough. Making it once would be easy, but...

Legally, you only have to be legal (registration, insurance) in your home state. (you may get hassled, but that is the law). Commercial use is another set of rules I believe.

50 state legal? Do you really need to be? Really?

Nothing wrong with toyota stuff. My only complaint with that version 4-runner was the stock rear overhang. I always wanted to build one with the longbed single cab wheelbase, but with the 4-runner length body. Basically it would be liked a bobbed bed with a bit more wheelbase....maybe 110-115ish...

Nothing will do all jobs at 100%, vehicle design is full of compromise....cost, complexity, size, etc. I really enjoyed doing the UA trip in my flat fender. Any vehicle would be fun on that trip as long as it stays together and running. I too am looking at building something a little more...

Some inspiration for you..... http://www.pirate4x4.com/forum/general-4x4-discussion/1260154-scout-800-woods-runner-build.html A very cool buggy in a body build using a scout body....and part of the frame too....

11 pounds...maybe even 12! :)

I think you can work around most of that. I would just do something like a Lotus7/Caterham front fender. The fender bolts right to the steering knuckle and is only like 1" off the tires. Then the fender just moves with the tire. Make the mount a quick disconnect so you can take them off...

Now's the best time to hash out ideas. You won't be pressed into doing something one way or the other for time...

Give up on this idea?

The old C-channel frame isn't going to hold up to too much shock. The frame and mounts will just start bending/flexing. Fox has a nice IFP shock out now that is running about $115. They are a 2" shock with a true floating piston to keep the oil and gas separate. You can take them apart for...

How about a nice hidden winch behind the stock bumper? If I remember right there is a nice slot in the bumper you could use to pass the cable through....

Thank you. I still drive it to work every day!