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Just a bit more..... A few tricks here. A paper template...yeah, you know that one already. Center punch the holes...yeah yeah. To mark the outside edges I 'wipe' a silver sharpie around the edge from the paper off to the steel. This gives me a nice edge..... I usually just spray glue the...

Couldn't you just use another winch solenoid upstream of the existing control pack? http://www.amazon.com/Warn-68379-WARN-Winch-Solenoid/dp/B001PJS51Q What is the purpose of the disconnect for you? Remote mounting the factory solenoid pack under the hood if that is possible would keep most...

Thanks! It is indeed a TIGHT fit on the front end with all that stuff. The winch is sunken to get the weight nice and low, plus it won't block the radiator. The steering box is in a position where it is low enough to work lock to lock but high enough to be protected by the front bumper. Still...

As long as your not going to do technical rock crawling.....A full size regular cab long bed truck is hard to beat for overall use. If you don't care TOO much about the body you can take them TONS of places you shouldn't. The thing I liked best about my truck was that I didn't need to change a...

Some progress.....finally! Tonight I got the steering box mount mostly built..... Hey look! Another paper template.... Cut, Cut, fold, fold..... Center punch the upper holes on the inside and outside. Mark them when you take the paper template off. Drill those four locations with a...

I am guessing that you don't want a full-size something? I would say shove the 350/465/205/D44/14-bolt in an FSJ. Trim out the fenders cleanly. 35s would be more than enough. A 110 wheelbase is just about right...not too big....not too small. The full size jeeps are smaller than your typical...

I'm fairly sure this is what I used... http://www.amazon.com/Unknown-XTRA-Seal-Bead-Sealer/dp/B000GKD722

That is interesting. It may be a combination of a small wheel and a big tire bead? It would be interesting to compare the od of the rim surface with some other wheels. I have had great success over the years using black bead sealant on the inner and outer bead surfaces. Its kinda a rubber gum...

I don't think the RHD thing will make 4wd that much harder. If you can find some back issues FourWheeler magazine did a most excellent project with one back in the 1990s ( ish?). You could also just do a transfer case with the drop on the other side. It would be tight, but possible. You are...

For a lower cost option why not just take this opportunity to bolt up a regular transfer case. This would give you a low range 2wd option and allow the option to add a driven front axle at some point in the future. With the automatic and 2wd, even' stock' low range gearing would be a marked...

So is your postal jeep 4wd or 2wd?

Just a bit of progress....but progress is progress. I got the winch mount mostly finished up ( for the mock up ). I will final weld everything during the tear down so I can roll the frame over and stuff. Not too much super trick stuff, but I did add a few details.... The top three...

Yup, a 15-16 degree cut takes up a lot of space! That should allow the A-pillar to follow the windshield almost exactly. I do think that I will have to relocate/remake a few things on the windshield to get all the stock features to work.

Thanks for contributing! The b-pillar will be behind the seats, not so far back it looks odd, but back enough that you shouldn't bump your head THAT much. It should also make getting in and out of the jeep a little easier too. With the low seating position and the smaller flat fender door...

This is pretty boring....but some decent little tricks.... I love these paper templates. All the holes have cross hairs for center punching. I had to make a slightly different template for an adjustment on the slot for the hawse. This is what the hole location cross hairs look like after...

Its basically because a lot of the 'expedition' crowd in the USA, especially jeep people, are coming down from the rock crawling high of the 90s and early 2000s. Ignore the comments that are not relevant. I find it REALLY funny that the cutting edge go-fast rock racer crowd is going IFS...

No new progress on the turbo swap. All my time and funds are going towards my Willys rebuild....

Looking at this chop I did while I was conceptualizing the entire project.... I think the b-pillar of the cage will need to be fairly far back. I am going to wait to finalize the cage dimensions until I get seats mounted....or at least the drivers seat. I need to take some more measurements...

Some rough thoughts on the cage....in pictures....

I have also started thinking more about the details on the cage. This is what a 1.5" tube end looks like cut at a 16 degree angle to match the windshield. I can JUST squeeze it onto the dash next to the factory glove box opening. In this position I would have to remove the factory pivot arms...