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Dave, you are correct. The 004 single phase conversion won't work on an 804. It's been tried...

Here's some pics of my truck, which originally had an LWS. Let me know what else you need to see and I'll be happy to take more pics...

I would think that new-in-the-can 6.2 motors would be readily available. Maybe Warthog still has one rattling around somewhere.....

Welding 3/8" plate open root with a stick welder is typically welded in 3 passes, using 1/8" rod at around 120amps. This is with the edges beveled. Doing it in a single pass, without beveling the edges will take considerably more power (and a different skillset). You may want to consider an...

100 hours = around 3000 miles more or less. What kind of welder? (I may be able to rule out an 802)

Do NOT put your transfer in low range, and your transmission in reverse unless you want to replace the transfer.

It feeds the low speed fan. You don't want to use that kind of tap for powering your stuff... evil tap. Ruins batteries....

Forklifted

If you're paying someone to do basic stuff on it, it will quickly become prohibitively expensive. Parts aren't all that expensive, and they are not difficult to work on.

I have nothing useful to add. Just a comment - When they pop loose unexpectedly in the middle of a long uneventful drive, they will literally startle the pee right out of you. Ask me how i know...

The last thing I want to do is to talk you out of a deuce. All the more so since I have one to sell you.... But let me muddy the waters a bit though - An 809series 5ton is like a larger deuce with power steering. It'll be no more complex to work on, although everything is heavier. The engine...

For the occasional or "just in case" self recovery I'd consider an electric winch to be OK. Bring plenty of snatch blocks... if you hit duty cycle just pause until it cools. If you're doin winch operations for the sake of winch operations (dragging trees all day etc), then you want a PTO...

Air shift transfer is preferred over Sprag. Dropsides are preferred over fixed. Dual circuit brakes are a huge plus. Winch adds about $1k in value. Check for mud in the differential fluid. Check for signs of abuse. I'll have one available in a couple of weeks. I'm planning a trip to OH later...

Hydraulic/PTO winches can typically pull far beyond the rated line pull.

The big difference between electric and hydraulic is duty cycle. Also, hydraulic winches tend to be severely underrated....

The DMV regs clearly state that historic registration is exempt from the inspection. However, DMV employees tend to be clueless and unhelpful, so they may have you do it anyway....

Be cautious about overtorquing lugnuts. Wheel studs will snap at the most inopportune moments. If memory serves, 500 ft/lbs is spec.

Thank you for following up to let us know what you found.

It's possible to weld magnesium. As stated above, inverted and dirty isn't the place to learn. ...

Bad ground. My guess says you sent about 100 amps through the ground on that side and burned it out... Did you move your ground clamp around while welding?