Recent content by jacksmad1

The 80 roller bearings were a little intimidating but just took a little time and bearing grease and they stayed where they were supposed to

Transmission finally got repaired. The shop had to start all over as they couldn’t get first rebuild to ever shift correctly. Thankfully the shop stood behind their work. After I got it home I had to rebuild the transfer case. One of the shifter forks totally worn down. Hard to shift into...

I have never measured the approach angle. Will have to see best way to do that. Not an issue for me because I don’t do any rock crawling etc.

Thanks for all the likes and comments. The M1009 is currently in the shop getting a transmission rebuild. The front pump was leaking down and the clutch pack went out. I removed the old one and installed a rebuilt unit and it would not shift correctly from 2-3 and then downshifted any time...

Finally got around to creating a narrated and indexed video of the process. Pretty much the same as the photos above with some additional information.

Notice in the previous photos the 2" rectangular tubing that is 1/4" thick that is mounted to the truck frame and extend to the front corners of the bumper. Also the top of the bumper and the winch plate are both fully welded to the uprights that are bolted to the frame which forms a box. Am...

Bumper mounted and first light bar installed. Finally all lights installed and ready to go.

Decided to go with black bed liner instead.

Added additional uprights for the brush guard. Also notice I had cut holes for blackout running lights and additional led driving lights. Made sure to properly weld all connections. First coat of paint.

I welded attachments to the bumper to bolt to the diagonal braces to the frame which are also bolted on. Box around winch totally welded on both sides to uprights at winch plate and bumper top for lateral strength. You can see the diagonal braces from the frame mounted on the M1009.

I bought the two pieces for the chain rings online from eBay so they would we beefy enough to hold up. So far most things were just tacked together, now I removed the bumper to burn it all in. Here you can see under the winch mounting plate and the 2" receiver. The receiver is not...

In previous photos I had also made the covers for the winch and fairlead holes. I welded some small tabs inside the winch hole to bolt to which can be removed when winch is installed. After studying on this setup for awhile I decided the uprights for the brush bar did not look meaty enough so...

Time for the brush bars to start. I had some 1/4" wall pipe laying around and cut it to fit.

Although when I cut the parts for one side and made mods to fit I would cut the other side at the same time but they would normally need some massaging as the fenders etc. would normally not be symmetrical.

Mounted tops on the bumper. Cut hole for the fairlead. The winch will actually mount inside the bumper.