I've been commuting with the truck and using it as a truck. The softopper comes of very easily allowing me to do real truck things with it. More projects I have:


But, here's some of what's happened.
Gear patterns on the front diff:




Zuk gave the the habeas blessius on the gears so I settled the solid spacer shims and put it together. For some reason, I was having some real struggles lifting that front differential into the spot and getting it bolted in. I eventually made it but it took me over an hour and it should have been a ten minute job. Driving in 4wd definitely is different with that Spartan Locker up front. My power steering screams at me when I'm under load on a sticky surface and trying to turn. That led me to decide to do another upgrade (no, not power steering upgrade.)

Seeing five of six lug-nuts on each front wheel was driving me crazy. I had picked up new studs months ago but was dreading taking the hubs off again.


I finally got around to it but when I did so, I also found my grease seals broken. So... back to town I go. I picked some up at NAPA and the left side got a new seal since I greased those bearings but the right side was already back together. I'll be putting the right grease seal in soon. The hub nuts and lock washers were beat so I ordered some of those from LCE. The right side was also missing the spacer that goes between the nut and the bearing. When those parts come in I will be replacing them on the left and pulling the hub off one last time on the right to replace that seal then the nuts. Man, I love doing a job three times!

Last big job was the air system with electrical. All the parts were in but I was missing the Argon for my new cheap TIG. I got an Eastwood TIG 200 and I'm actually really impressed. After doing some practice and official business with it, I started on my air system. Welded the air fitting in the end then I welded the bung for the drain.


Then welded on the mounting tabs.


And the tank was complete. I hoped it wouldn't explode under 150psi.


I sure think it turned out great; no undercutting on the tank and good penetration. I measured and drilled holes in the mounting tabs then lifted it up under the bed between the driveshaft and fuel tank and marked the stiffeners under the bed. Then I took the tank down and drilled. It landed exactly where I wanted. I has some old 3/8" air hose that I will be replacing since it is brittle but used it to plumb the tank and air chuck for tire filling.




I installed the Viair compressor behind the fusebox and added another fuse box to the engine bay inside the right fender.


The wires for the switches run up along the firewall and through a grommet by the left door. I hacked some holes into my dash the only place I could find space for the switches and made paths for all the electrons. I didn't wire the illumination circuit yet though.


I took the truck wheeling before and after the rear locker. Same trail, same obstacle. It's the start of Behind the Rocks just South of Moab. With just the front locker, I'd get quite a bit of wheel hop still and couldn't make it up the first big obstacle which resembles a waterfall. I took some photos on that first outing.


Got some angle here.


Then today I worked in the morning unexpectedly and was done right around the time church let out so I met up with the wife for lunch. Then we started heading home and I called her to ask if she wanted to try that same trail. We met at the trailhead, she hopped in, and off we went bouncing up the trail. We got the the obstacle and it took quite a few tries but once I hit it at the right angle, I made it up. The compressor, tank, and locker all work exactly as intended. I still need an air hose to air up tires but that's small beans. I checked when I first installed the tank; my tire was at 22psi. I added air until the compressor started (110psi) and I had added 5psi to the tire leaving me at 26psi and it would have taken lots more before I drained the tank. Not shabby.

If I intend to do any more serious crawling, I need 4.7 gearing in the transfer case or dual cases. That's next year though.

I'd say this build is mostly done and a complete success. I am aiming for some serious travel in July for some much needed time off. I should still buy or build some bumpers but I'm not overly concerned yet.

As for the LCE order, I think something in my 4wd drivetrain is wonky. The transfer case has a rattle that isn't RPM or load dependent and it goes away in 4WD or if I engage the front hubs. So I ordered a transfer case major overhaul kit. That will be happening soon. I also ordered a twin stick for the forward shift T-case so I can be in low range with the rear locked and still be able to steer easily. I would recommend that modification to anyone with an auto locked front. What I forgot to order was the transfer case mount. Mine is saggy and floppy. I need a new one and will be calling them tomorrow to see if that can add it to my current shipment. I already have two new front fenders in a box at work that I need to paint. Also have two new front corner lights. I have a reverse switch that I plan to finally install. I have two harness pigtails, one for the O2 sensor and one for the speed sensor that need spliced in. I plan to finalize my dual band radio install and make a nicer mount for the head unit. Maybe get some interior stuff some day. So the list is still long but I'm almost comfortable enough to slow down the long days in the shop.