Work accomplished this weekend:
I made bottom frame plates for the rear. These provide additional mounting surface for the rear bumper. I felt like it would need more weld area for the rear bumper if I ever use it at a recovery point. Of course, I haven't put any recovery points on the bumper yet...
I drilled new mounting holes in the factory gas tank skid plate and re-mounted it. I wanted to make a fancy new one, the factory one fits and works, so for now that's what I'll be using.
I put back on the factory exhaust pipe between the exhaust manifold and the cat (I'm sure this pipe has a name, but I don't know what it is). I had to tweak it a little to make it fit around the radius arms and end up in the right spot in the skid plate, but it turned out nice. It has enough clearance around everything, and the catalytic converter fits nicely on the end of it where I need it. Unfortunately my muffler hasn't shown up yet, so the exhaust currently comes right out of the cat above the skid plate. It's much quieter than just ending at the exhaust manifold, and if my muffler doesn't show up soon I may end up wheeling next weekend with it the way it is. Oh, I also reinstalled the O2 sensor. Hopefully I can get the "Maintenance Required" light to turn off.
Speaking of skid plates. I built one. It's got ten bolts that hold it on, and I missed (just barely) on two of the holes, so I need to drill them out a bit to get the last two bolts to line up.
I charged and reinstalled my shocks (thanks Chad!). They work like shocks now.
I even took it for a little test drive and got the tires dirty!
Everything seems to be working. I could almost wheel it like it is. There are a few things that I have to do before the first trip, and then a lot of things to do to "finish" it.
Must do before Moab:
I need to order coilover springs tomorrow (or tonight...). Now that I've got the shocks charged, I'll throw a few sticks of tube up on the roof to simulate the extra weight it will eventually have, and then figure out what additional springs I need. I'm confident that I can use the four springs I have on it now, but I need to order the top springs for each corner.
I need to install the winch control box and the winch rope.
Clean all the junk out of the inside and put the seats back in.
I still don't have the transmission wired. I still need the plug that goes into the TCU. It seems to shift okay with just the mechanical shifter. I have to shift for it, no automatic shifting, but I could get by like that for one trip. Am I doing any damage by shifting like that? I know the torque converter is never locking up, but I'm not that concerned about fuel economy at this point.
I need to cut the front fenders into the shape they'll end up being. The rear is cut rough, but the front just looks hacked.
Hopefully it doesn't rain next weekend. I hate rusty tube.