The only trick I know is to keep cutting 'till nothing rubs.
you mean there is some other trick?
The only trick I know is to keep cutting 'till nothing rubs.
Nope, stock rover axles with ashcroft shafts, Detroit in back (Great Basin shafts) and TruTrac up front. This was a perfect set-up for all year wheeling. If I didn't care about keeping the body straight, I would have kept this one!
As for trimming against the door, I split the seam, cut the inside sheet, then notched and folded over the outside sheet to cover up the new seam. I had to tear out the rubber seal and then buy some replacement seals with the sticky tape. I'll try to dig up some pics, but i'm sure it wont be that different for a DI.
Another option might be to lengthen the radius arms an inch or so. I did that with my DII, but again, the DI arms might be different. The DIIs are cast, so I had them professionally welded. With that mild of an adjustment, I didn't need to relocate the spring perches/buckets at all. I did get rid of the watts linkage, but I don't know if DIs have the watts or just a panhard. Man! this is making me want to get a DI to build!!
Also, call Bill over at Great Basin Rovers in Salt Lake (http://gbrutah.com or801.486.5049). He'll talk your ear off and let you know anything and everything that you should do... He's a great guy to get to know if you are going to stay with the rover for a while. I didn't buy everything from him (rovertyme has some great stuff), but he is a well of knowledge and will spend the time to chat. He also stands 100% behind his stuff.