Here's a list of mods and links to the page that the discussion starts.
• First and second day of wrenching SAS: (Cutting, torching, and magdrilling) http://ttora.com/forum/showthread.php?t=102614
• Third Day: Welding brackets/Test fitting: http://ttora.com/forum/showthread.php?t=102614&page=3
• Fourth day (Shocks and final Pics): http://ttora.com/forum/showthread.php?t=102614&page=8
• Shortening Caps on Weld Rims: http://ttora.com/forum/showthread.php?t=102614&page=12
• Welding shock mounts/Chevy Spring Install: http://ttora.com/forum/showthread.php?t=102614&page=13
• Rework IFS Driveshaft: http://ttora.com/forum/showthread.php?t=102614&page=15
• Crossmember Modification+Install DS: http://ttora.com/forum/showthread.php?t=102614&page=16
• First Wheeling Trip + Front Wheelwell Clearance: http://ttora.com/forum/showthread.php?t=102614&page=18
• Crawl Box Install (First Day, old design): http://ttora.com/forum/showthread.php?t=102614&page=25
• Crawl Box Install (Second Day): http://ttora.com/forum/showthread.php?t=102614&page=27
• Crawl Box Install (Shifters): http://ttora.com/forum/showthread.php?t=102614&page=29
• Crawl Box Install (Complete): http://ttora.com/forum/showthread.php?t=102614&page=30
• Crawl Box Install (Source of Leaks, and Transmission Poly Mount Fab): http://ttora.com/forum/showthread.php?t=102614&page=32
• Crawl Box Install (Final Crossmember modification): http://ttora.com/forum/showthread.php?t=102614&page=34
• CV Driveshaft part info: http://ttora.com/forum/showthread.php?t=102614&page=35
• Bumper Fab: http://ttora.com/forum/showthread.php?t=102614&page=36
• Bumper Fab Day two: http://ttora.com/forum/showthread.php?t=102614&page=37
• Bumper Fab Day 3, Foglight Install, CV Driveshaft Repair: http://ttora.com/forum/showthread.php?t=102614&page=39
• Crawl Box Install Part 2 (Sealing leaks): http://ttora.com/forum/showthread.php?t=102614&page=40
• Testing the crawl box, Panhard bracket Fix: http://ttora.com/forum/showthread.php?t=102614&page=41
• Trunnion Bearing PN,s Frombe Arms: http://ttora.com/forum/showthread.php?t=102614&page=42
• 4.88 Regear: http://ttora.com/forum/showthread.php?t=102614&page=43
• Corner Weigh + PSC Pump fitment: http://ttora.com/forum/showthread.php?t=102614&page=48
• PSC Pump install + Hydro Assist: http://ttora.com/forum/showthread.php?t=102614&page=49
• FOA Install: http://ttora.com/forum/showthread.php?t=102614&page=52
• Rear Brackets for FOA Shocks: http://ttora.com/forum/showthread.php?t=102614&page=53
• PSC Overflow bottle: http://ttora.com/forum/showthread.php?t=102614&page=54
• Tundra Brake Swap: http://ttora.com/forum/showthread.php?t=102614&page=55
• Lic. Plate lights + Raceline Beadlock Install: http://ttora.com/forum/showthread.php?t=102614&page=58
• Crawler Box Fretting: http://ttora.com/forum/showthread.php?t=102614&page=59
• Corner Weigh Round 2 (With COG numbers!): http://ttora.com/forum/showthread.php?t=102614&page=61
• Rear Gears Blown, avoid JAWs gear and axle: http://ttora.com/forum/showthread.php?t=102614&page=61
• Rear Brake Caliper Info for Full Float: http://ttora.com/forum/showthread.php?t=102614&page=62
• ZUK’s rear gear install, Full Float Install: http://ttora.com/forum/showthread.php?t=102614&page=63
• Front Gears bad, Avoid JAWs gear and axle!: http://ttora.com/forum/showthread.php?t=102614&page=64
• http://ttora.com/forum/showthread.php?t=102614&page=65
• Front Gear Install (Nitro 4.88 with 29 Spline): http://ttora.com/forum/showthread.php?t=102614&page=66
• http://ttora.com/forum/showthread.php?t=102614&page=67
• Full Float Install + Prop Valve: http://ttora.com/forum/showthread.php?t=102614&page=67
• Full Float Install (E-brake + Parts List): http://ttora.com/forum/showthread.php?t=102614&page=68
• Full Float Install (Final Assy): http://ttora.com/forum/showthread.php?t=102614&page=69
• Crawl Box Fretting (Disassembly): http://ttora.com/forum/showthread.php?t=102614&page=69
• Crawl Box 2 (Assembing a Crawl Box Without Leaks [Detailed]!): http://ttora.com/forum/showthread.php?t=102614&page=70
• http://ttora.com/forum/showthread.php?t=102614&page=71
• Crawl Box 3 (Leaks Back, almost lost case on the freeway): http://ttora.com/forum/showthread.php?t=102614&page=73
• Crawl Box 4 (Machined hardware to prevent leaks + movement): http://ttora.com/forum/showthread.php?t=102614&page=75
• DIY Bubble Balancing Beadlocks: http://ttora.com/forum/showthread.php?t=102614&page=75
• FOA Shock Rebuilding + Reshimming: http://ttora.com/forum/showthread.php?t=102614&page=76
Well, finally decided to do it. Bought the axle and hardware from jh3. I started rebuilding it after one of the hubs wouldn't unlock. One thing lead to another (I'm not going to get into it and I don't want this to be a bashing thread) but I ended up going through the whole axle.
First night of wrenchin
All assembled, painted, and built:
Axle specs:
Toy axle (I believe a 83) chopped, and flipped, knuckles rotated, balls gusseted, axle gusseted, 1/4" plate for the cover, plated under the 3rd.
ARP Knuckle Studs
V6 3rd with 4.10's (Now with 4.88's)
30 Spline Chromo Longs
Allens from the inside out to replace the studs on the 3rd
Marlin Seals
TG High Steer kit w/FJ ends (Now 4x4lab Frombe Steer Arms)
RuffStuff Specialties Spring Perches
IFS hubs
IFS calipers (they're confirmed that they are not V6)
Sky IFS widening kit
ARP hub studs
Longfields chromo hub gears
FJ rotors
TG rock rings
SAS specs:
35" BFG KM2's
Marlin 4" Springs
5/16" spring crossmember, with 3/8" perches
Frame plated from cab forward
5/16" shackle perches
Panhard bar with links from Ballistic
63" Chebies
Borgeson Steering Shaft and hoses from Bentup
And a lot of other parts.
Note that I didn't really buy any metal parts, except for the rear leaf perches. I had the shackles made from 5/16" plate, as well as the brackets, perches, steering box mounts, and frame braces.
The rig before the chop:
• First and second day of wrenching SAS: (Cutting, torching, and magdrilling) http://ttora.com/forum/showthread.php?t=102614
• Third Day: Welding brackets/Test fitting: http://ttora.com/forum/showthread.php?t=102614&page=3
• Fourth day (Shocks and final Pics): http://ttora.com/forum/showthread.php?t=102614&page=8
• Shortening Caps on Weld Rims: http://ttora.com/forum/showthread.php?t=102614&page=12
• Welding shock mounts/Chevy Spring Install: http://ttora.com/forum/showthread.php?t=102614&page=13
• Rework IFS Driveshaft: http://ttora.com/forum/showthread.php?t=102614&page=15
• Crossmember Modification+Install DS: http://ttora.com/forum/showthread.php?t=102614&page=16
• First Wheeling Trip + Front Wheelwell Clearance: http://ttora.com/forum/showthread.php?t=102614&page=18
• Crawl Box Install (First Day, old design): http://ttora.com/forum/showthread.php?t=102614&page=25
• Crawl Box Install (Second Day): http://ttora.com/forum/showthread.php?t=102614&page=27
• Crawl Box Install (Shifters): http://ttora.com/forum/showthread.php?t=102614&page=29
• Crawl Box Install (Complete): http://ttora.com/forum/showthread.php?t=102614&page=30
• Crawl Box Install (Source of Leaks, and Transmission Poly Mount Fab): http://ttora.com/forum/showthread.php?t=102614&page=32
• Crawl Box Install (Final Crossmember modification): http://ttora.com/forum/showthread.php?t=102614&page=34
• CV Driveshaft part info: http://ttora.com/forum/showthread.php?t=102614&page=35
• Bumper Fab: http://ttora.com/forum/showthread.php?t=102614&page=36
• Bumper Fab Day two: http://ttora.com/forum/showthread.php?t=102614&page=37
• Bumper Fab Day 3, Foglight Install, CV Driveshaft Repair: http://ttora.com/forum/showthread.php?t=102614&page=39
• Crawl Box Install Part 2 (Sealing leaks): http://ttora.com/forum/showthread.php?t=102614&page=40
• Testing the crawl box, Panhard bracket Fix: http://ttora.com/forum/showthread.php?t=102614&page=41
• Trunnion Bearing PN,s Frombe Arms: http://ttora.com/forum/showthread.php?t=102614&page=42
• 4.88 Regear: http://ttora.com/forum/showthread.php?t=102614&page=43
• Corner Weigh + PSC Pump fitment: http://ttora.com/forum/showthread.php?t=102614&page=48
• PSC Pump install + Hydro Assist: http://ttora.com/forum/showthread.php?t=102614&page=49
• FOA Install: http://ttora.com/forum/showthread.php?t=102614&page=52
• Rear Brackets for FOA Shocks: http://ttora.com/forum/showthread.php?t=102614&page=53
• PSC Overflow bottle: http://ttora.com/forum/showthread.php?t=102614&page=54
• Tundra Brake Swap: http://ttora.com/forum/showthread.php?t=102614&page=55
• Lic. Plate lights + Raceline Beadlock Install: http://ttora.com/forum/showthread.php?t=102614&page=58
• Crawler Box Fretting: http://ttora.com/forum/showthread.php?t=102614&page=59
• Corner Weigh Round 2 (With COG numbers!): http://ttora.com/forum/showthread.php?t=102614&page=61
• Rear Gears Blown, avoid JAWs gear and axle: http://ttora.com/forum/showthread.php?t=102614&page=61
• Rear Brake Caliper Info for Full Float: http://ttora.com/forum/showthread.php?t=102614&page=62
• ZUK’s rear gear install, Full Float Install: http://ttora.com/forum/showthread.php?t=102614&page=63
• Front Gears bad, Avoid JAWs gear and axle!: http://ttora.com/forum/showthread.php?t=102614&page=64
• http://ttora.com/forum/showthread.php?t=102614&page=65
• Front Gear Install (Nitro 4.88 with 29 Spline): http://ttora.com/forum/showthread.php?t=102614&page=66
• http://ttora.com/forum/showthread.php?t=102614&page=67
• Full Float Install + Prop Valve: http://ttora.com/forum/showthread.php?t=102614&page=67
• Full Float Install (E-brake + Parts List): http://ttora.com/forum/showthread.php?t=102614&page=68
• Full Float Install (Final Assy): http://ttora.com/forum/showthread.php?t=102614&page=69
• Crawl Box Fretting (Disassembly): http://ttora.com/forum/showthread.php?t=102614&page=69
• Crawl Box 2 (Assembing a Crawl Box Without Leaks [Detailed]!): http://ttora.com/forum/showthread.php?t=102614&page=70
• http://ttora.com/forum/showthread.php?t=102614&page=71
• Crawl Box 3 (Leaks Back, almost lost case on the freeway): http://ttora.com/forum/showthread.php?t=102614&page=73
• Crawl Box 4 (Machined hardware to prevent leaks + movement): http://ttora.com/forum/showthread.php?t=102614&page=75
• DIY Bubble Balancing Beadlocks: http://ttora.com/forum/showthread.php?t=102614&page=75
• FOA Shock Rebuilding + Reshimming: http://ttora.com/forum/showthread.php?t=102614&page=76
Well, finally decided to do it. Bought the axle and hardware from jh3. I started rebuilding it after one of the hubs wouldn't unlock. One thing lead to another (I'm not going to get into it and I don't want this to be a bashing thread) but I ended up going through the whole axle.
First night of wrenchin
All assembled, painted, and built:
Axle specs:
Toy axle (I believe a 83) chopped, and flipped, knuckles rotated, balls gusseted, axle gusseted, 1/4" plate for the cover, plated under the 3rd.
ARP Knuckle Studs
V6 3rd with 4.10's (Now with 4.88's)
30 Spline Chromo Longs
Allens from the inside out to replace the studs on the 3rd
Marlin Seals
TG High Steer kit w/FJ ends (Now 4x4lab Frombe Steer Arms)
RuffStuff Specialties Spring Perches
IFS hubs
IFS calipers (they're confirmed that they are not V6)
Sky IFS widening kit
ARP hub studs
Longfields chromo hub gears
FJ rotors
TG rock rings
SAS specs:
35" BFG KM2's
Marlin 4" Springs
5/16" spring crossmember, with 3/8" perches
Frame plated from cab forward
5/16" shackle perches
Panhard bar with links from Ballistic
63" Chebies
Borgeson Steering Shaft and hoses from Bentup
And a lot of other parts.
Note that I didn't really buy any metal parts, except for the rear leaf perches. I had the shackles made from 5/16" plate, as well as the brackets, perches, steering box mounts, and frame braces.
The rig before the chop: