front axle work

Scouts had 0* caster built into their axles, a spring over lift needs roughly 6* (from what I've researched) to keep the pinion angle happy on and off road.  
After finding 0* with the stock pads on the stands, I used a punch to mark 0* on the tube and knuckle, then rotated the axle/pads to 6* and re punched. mark them away from where the grinder will hit.

This is the amount that the steering knuckles need to move. 

Just cut and rotate them- easy right?  Figure 2+ hours per side if you

haven't ever done this before.

Tools needed: 4.5" angle grinder with grinding wheel and minimum 2 cutting wheels,

wire wheel, welder and accessories, protractor,  stands,

 3lb and 5 lb sledges ( i used the backside of the wood maul)

marker, punch, and loss of mental function for doing this.

you can see the hairline crack- this is where the tube meets the knuckle..you have to grind deep enough to find this, deep enough into the knuckle to remove all the weld, but not too much.

This is the stock 0* before knuckles

note the cleanliness of the driveway before pounding

this is the 6* (far side) and 0* close side

all this dirt came out of the axle tubes because the

axle seals were still in.  BFH on right side of picture.

Here is where a lot of time was taken up- note the ring between the tube and knuckle

in the middle.  This was a teeny tiny amount of weld (maybe an inch) that penetrated deeper

than the rest at the factory- the result was a lot of pounding to get it to rotate

Safety note** I re-welded the knuckles using 4 + passes with a 180A welder to fill and strengthen

the ground out parts.  If you have any doubts - hire a professional

welder to get the parts reunited!  If not done right, figure the entire

wheel assembly rotating in a weird direction , locking up your steering,

or leaving the vehicle while driving. (either is bad)

meet the new gears / mini locker rev1

Ok- so the jeep is now a jeep-chevy-scout-isuzu hybrid.  It IS all American though- the isuzu came with a rear dana 44  (courtesy of the USA)  with 4.30 gears. (with a custom center pumpkin)
The differnce is that the isuzus ring gear is thicker and the pinion gear , the gear side bearing is puny compared to the scouts the yolk side is exactly the same.

*****update...  isuzu had proprietary dana 44s with special carriers and pumpkins-  they won't work in US vehicle dana 44s- they are >1/2" off!!!!******** regardless of what the guy that sold them on ebay says.
It falls half way through the scouts race before seating.  the isuzus bearing race wallers around in the scouts housing.

The first time since 1974 that these two guys have parted ways

Note the scouts ring on the left, and the isuzus on the right. 

 The  inner spacing ring measured exactly the same between the two, it just that one on the right is thicker.

Because of this, if the carrier pin ever has to come out, the ring has to come off.

Here's the pinion and all accessories from the rear axle.

The shims go between the housing and the bearing races.

Note the mangled oil slinger next to the gear.  somehow

parts of it are chewed off.  It turns out the rear had koyo

bearings but still had timken carrier

bearings, so it had been gotten into before.

isuzu on stock scout carrier up and scout ring lower

---------------------------------

 a mini spool isn't just a name- it really is small

Here's what it looks like taken apart. The round parts go into the side of the carrier, and the carriers cross pin goes through the square blocks.  100% lockup.  If I want to change it back later- the spider

gears can be back in within an hour.

post incident assessment

Cleaned everything out of the commando after megarun. The jeep seems to be in very good condition considering being bounced all over in E. Texas.   Found dirt, tree branches, and that all the tools in back were bounced around so much that the came out of their cases. (including the winching kit and a 200 pc electrical connector kit.)
After 1/2 hr picking up parts, I was advised by the boss that the jeep needs bucket seats and a roll cage before it goes out with the family in it. 
Ok twist my arm.  I'll get on it after the rest of the repairs.
Still have axles (coil sprung front??), front shocks, driveshafts, POWER steering, trim bodywork, armor, seats, herculiner, and a cage.
The easiest coil front would be to make it like a land rover defender / early bronco with the coil buckets/ shock towers
and positioning arms off the frame. 
This guy hob-nailed one together in Norway: http://www.fullsizejeep.com/1024/p_suspension.htm

Megarun v2.0

screw it, i'm wheeling it with a dana 30 and 44 tomorrow.   if it can make it around the block by itself, it can make it out there. going to bolt on the rear bumper and skid plate and tow hooks and just go for it.

Pre incident. just got done running some 3 diamond trails, the narrow wheelbase

is a big plus cutting between trees, but the manual steering eats that up.

Got so off camber on politician trail that a guy had to push on the passenger

corner of the roof to keep it upright until the jeep got to where it could right itself.

Wheel base and lift height are excellent.

Rocker knocker.  

The jeep covered 3/4 of the rock garden

without any dings except for a shock just driving it slow. 

One time during competition though and poof- insta dent!

  I obviously didn't get the side plates on, but in a way its good.

The plates would have been dragged off by the rear tires hitting the corner of the

wheel flares.  So now I know what to trim.

The previous test run on the rock garden proved that the shocks weren't up to the test.

It flexed the eye and upper mount off the shock, and the shock was dangling

by the 3/4 mark of the course.

Everybody couldn't believe that 36" tires were shoved up that

 far into the wheel well

See whats missing from the previous posts pics.

All I can say is re check everything before going out. 

Oh BTW- I installed a Clarke 180 (very rare option ) posi locker

in the rear.  Worked awesome.

Heres what stopped me dead on the rock garden during competition.  The front end flexed farther than the driveshaft

would allow and ripped the yolk from the shaft.  An in-situ weld kept it going for the rest of the day.

 The "mighty" dana 30- still in one piece after being bashed on boulders.  Still can't

wait to get the d44's on ....

rear shocks

The fronts were put on using original lower mounts and elevated upper mounts. supposed to be bronco shocks.
  blah. boring, not worth a picture.

The rear shocks needed all new mounts to make these work.

The original shocks went from the ubolt plate up and backwards

to the frame on the outside of the springs

The rear are supposed to be for a blazer, they came with upper studs.

some angle was cut and bolted to the frame, then some c.r.e.w.

tube was welded across that

the lowers are 1/2 x 3" bolts welded to the axle tube and spring perch.

body armor

BTW thanks to Barney and Todd for the help w brakes and the armor.

just made a cardboard rocker template into a 3/16 x4" rocker guard. 

 I don't know how this thing will be installed yet because the jeeps rocker

is a hollow box that cant be accessed for bolts.  I think if it were welded on it would

fall off with the first or second rock or tree it hit. hmmmm....

The gas tank skid plate is taking shape 3/16" w a little 1/4" metal thown in for kicks

 

Transfer case skid plate-  1/4"

Angled to match the crossmember support.

Exhaust v1.1

I, and the jeep are not welcomed back at the muffler shop.  JK,  forney muffler put on a KILLER exhaust on the jeep,  it stayed an extra 5 hours on the rack, but the exhaust is tight and almost completely in the frame.
Chase, the exhaust genius, said he's never had such a tight spot to work in.
 It has duals halfway down the pipe, then under the rear seat it goes through the muffler ,
over the axle and outside the rear drivers side frame.

The only problem with it being so tight is that the exhaust will have to be loosened

to get to the transmission shifter later.....

high and tight.  I could also snorkel it...

he left some extra pipe on so i could run it through the bumper