My new project

[Stocker]

Originally Posted by Ronnny

The 203 transfer case compared to any other one is a boat anchor. I would guess near 150 more lbs than the 205

Not quite.... it just feels that much heavier when it's lying on your chest.

http://www.4wheelingplus.com/tcase.asp

NP203 - 165 lbs.
NP205 - 138 lbs.
NP208 - 79 lbs.

[coggonobrien]

is there any major reason to switch to a np205 from a np203??

[Tex_50613]

Originally Posted by coggonobrien

is there any major reason to switch to a np205 from a np203??

part time 4x4 for one, gear drive so there isn't a chain to slip for another, there are additional reasons for people to swap but those are the 2 that pop to my mind, I personally swapped to a 205 from a 208 to be able to twin stick the t-case (which I did before I installed the t-case) but that aside it's looking like a nice project so far

[rayfinseats]

I made a front bumper tonight out of 5 pieces of 1/8 x 4 steel plate. I took about 2 hours. AND I GOT THE STEEL FREE. I still need to add **** to it like a cow catcher and signals, driving lights etc. I hope it comes out a little lighter than the stock one but it seemed heavier than I thought it would. It looks great. Too bad I couldn't get free aluminum.

[rayfinseats]

Still have to brace, lights, etc.

[Stocker]

Since you're going for lightness, why not fab a fiberglass front bumper? Better still if you could adapt some sort of OEM plastic front end, especially if it incorporates a bit of aero improvement.

[rayfinseats]

Cuz it will be a daily driver and I want some protection and if I hit a deer I don't want to have to rebuild the whole truck. I think there are better places to remove weight, like the hood and bed. I'll weigh it when I get done and see how I did. 1/8th" isn't that heavy. I will keep that in mind. Maybe I'll do an aluminum one later.

[rayfinseats]

I finished the front bumper and it weighs about the same or less than the stock bumper but will be much more versitile.

[rayfinseats]

[rayfinseats]

I got the bolts out of the box last weekend. I drilled them out from the top, disconnected both fuel tank tubes. Now I can start fab on the new box as soon as I can find a scrap yard to take the rusty box.

[rayfinseats]

Dumped the box today. It weighed about 600 pounds (640 with an axle hosing in the back). Truck weighed 4900 with the box. DOWN TO 4,260 POUNDS

[rayfinseats]

I got my lights wired. It seems I have halogen bottom bulbs and they are really bright. They seem brighter than all those 100 watt harbor freight lights I have on the front. Do you think I'd be better off with some of those rectangular halogen driving lights? Does it make much difference if they are mounted higher or not really?

[Stocker]

Originally Posted by rayfinseats

I got my lights wired. It seems I have halogen bottom bulbs and they are really bright. They seem brighter than all those 100 watt harbor freight lights I have on the front. Do you think I'd be better off with some of those rectangular halogen driving lights? Does it make much difference if they are mounted higher or not really?

You said it right there -- high quality lamps are far better than cheap junk with high-wattage bulbs.

I would stick with a reputable European brand such as Cibie or Hella. Be sure to use relays. And yes, driving lamps generally work better if they are mounted a little higher, opposed to fog lamps which usually mount lower. Round vs rectangular is more a styling choice... but IIRC, round has more effective beam patterns.

For more good info than you may ever need, try http://www.danielsternlighting.com/. He really knows his stuff.

[rayfinseats]

Thanks Stocker at least someone is reading my jabber. I have the frame and sides and tailgate made for the box. 50" by 96" by 18". 1/8 x 2 x 2 angle iron. Very light and sturdy. I'm either going to make aluminum fenders outside the box or maybe plastic trailer fenders. http://www.cabelas.com/catalog/large...oductId=737092. Oh, and the whole thing is hinged in the rear for now so I can work on the chassis.

My camber is way off on one front wheel. Does that mean my axle housing is bent ?? Bottom of tire leans out. Bought it that way. Not real bad but you can see it looking straight on.

[rayfinseats]

Added 6x2 oval LED tailights off the box. Similar to...


http://www.superbrightleds.com/cgi-b...trb.htm#photos

I got the tail light and brake lights working. I think they will blind the people behind me at night he he. Will post pics soon.

[rayfinseats]

[rayfinseats]

I added five 2x2 floor braces and 1/2 oak floor for now. I put a 20 gauge sheet of steel in the tailgate (cuz I have magnetic signs for my business) and two 1/8 by 2x2 angle iron in the tailgate. The gate latch works smoothe as a factory latch. I added two more uprights on the sides. I also have 2 hitch pins holding the front of the box down and can tilt it 90 degrees if need be. Thinking aluminum sheets on the sides. Taking it in soon for front end work and alignment then I'll go to town on the bodywork and paint.

[MTCK]

Truck is looking good. Just for giggles I went across the scale last weekend and my 77 is 4880 with a 250 lb driver, two empty gas tanks and nothing in the bed.

[rayfinseats]

4200 was with a 180 LB driver but I had change in my pockets...

[rayfinseats]

1/2" floor an 1/4 inch sides. Coated with Urethane

Slow progress. But progress none the less. Kinda looks like a coffin. Bad drivers piss me off maybe it will be one.

[rayfinseats]

Almost done with the re-wire. Having the front end rebuilt and aligned within a couple weeks. Wish I had a couple more leafs for thhe front end. I need about 4" more to level it out now.

[rayfinseats]

I found a guy with a local junkyard on his property that has tons of parts. Picked up a perfect rt. front fender and dual electric fans for $60.

[rayfinseats]

Got the fender mounted. LOTS of hidden bolts in that thing... Got the front end all rebuilt with new parts. Need paint, exhaust and have a few issues with gauges not working and gas tank selector not working but I've been driving it. Have electric radiator fan, aluminum water pump, headers, and a performer intake to install one of these days also picked up used.

[rayfinseats]

SO how do you get to the tank selector valve? It looks like mine has some kind of cover over it. The truck had all the options and has all the skidplates under it.

[rayfinseats]

Added rear plastic trailer fenders. Not sure about the look but was concerned about running with no fenders.