Demolition Status
Jack Truck Done
Place on tall jackstands Done
Remove Skid Plates & armors Done
Remove front wheels Done
Dismantle Brake Systems Done
Dismantle Spindle A-arms and UCA & CV joints Done
Remove front coilovers Done
Remove bumper & winch Done
Remove remove front grill
Remove rack & pinion
Remove drive line Done
Remove ARB line
Remove Differential
Cut off remaining bracketry
Fabricate radiator protection Done
place weight of truck onto radiator brace stands N/A
Frame Prep
grind frame flat
weld on front frame reinforcements
grind and weld frame reinforcements at the rear
Steering
take out steering firewall
weld in new firewall for PS
Cut driver's side wheel well forward to cross-brace
align PS straight up and down and as far forward as possible
spot weld power steering pump brackets
test fit and re-do if necessary
weld brackets into place
install power steering box
install and Check clearance of PS shaft through to PS box
Engine
Remove oilpan & pickup
install T100 oilpan & pickup
Intall Links to Axle
Set axle in place
Use plumb bob to center
Set pinion angle
Mock panhard and draglink angles
support transmission with jack or something
Remove stock t-case cross member
Remove stock drive shaft
remove stock t-case
mate crawl box to transmission
check & cut location of hole for t-case shifter through floorpan
mate t-case to crawl box
install t-case x-member from FROR
Setup shifters
Measure link locations & test in calculator
Fabricate frame link cross member
Cut front end of links to proper lengths
Weld Tube Adapters to links
Tack lower links
Stuff axle as high as possible
Check that pinion angle and axle center is maintained
Check with collapsed shocks length
Fit and tack upper link ensuring no conflict with panhard
Ensure axle is still centered
Fit and tack panhard parallel to draglink
Check Tie Rod location with hydro assist
Lower to ride height
Check with shocks at collapsed length plus ~3 to 5 inches.
Stuff axle as high as possible & check tire clearance
Cut into wheelwell if needed
Adjust as needed
Articulate to check for binding & Rubbing
Install panhard
Adjust axle to desired ride height
Make sure axle is centered and pinion angle is set properly
spot weld panhard brackets to axle & frame
install panhard
confirm DL and PH are parallel
Check Tie Rod location with hydro assist
cycle for binding and clearance and correct if needed
Shocks
Measure location and distance for top of shock hoop and mounting surfaces
Tack Shock hoops to frame
install shocks sans 1 spring and cycle to check binding and clearances
alter shock mounts if necessary…ride height under 25" desired (23" if still on 33's)
set back to ride height
weld in cross brace between steering box and other frame rail
weld up a new platform for the battery (see Dean & steve's work)
install battery platform to top bolt of PS box
Fix if issues
Shock Hoop Cross Bracing
Spot Weld Tubing clamps to shock hoops (may need to drill thru holes in sheet metal)
bend tubing over engine
spot weld tube clamps to engine bay shock hoop reinforcements
clamp reinforcements through engine bay
Final Setup
final weld on all brackets and whatnot if looking good.
paint
bleed brakes
Install shackles & springs to rear