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1986 K5 The over-achieving grocery getter

1986 K5 Chevy Blazer
Finished up a quick skid plate for the gas tank. I now have at least some piece of mind for BB2019. I just had a buddy bend a box out of 7 gauge (3/16") grade 50. I welded a stick of 1" square tube in the front for support and the back I figured the bent box would be strong enough.

It got bolted directly to my Curt hitch with four grade eight 3/8" bolts while the front I just cut two 7" sticks out of the 1" square tube to reach up to the crossmember at the front of the gas tank. Fizz can was the covering of choice until after BB2019 I will probably powdercoat it. Overall I am happy with how it came out, and I know its not something I could support the Blazer with but its enough that if I tag something I at least won't puncture the gas tank.

I suppose this is also a good time to ask... If you look at the first picture below showing the kickers to the gas tank crossmember you will see that I have gear oil pretty much everywhere. It doesn't do it just around town but any sustained driving on the highway for 20 minutes or more it will puke fluid out of the breather. It started happening on the way down for Fullsize Invasion but I think I may have had it overfull before FSI2019 but I have been driving it with the new 1 tons for several months before that. It only started to puke it out coming into Moab for the last 100 miles from Grand Junction. Then it did it the entire way back(we did add fluid feeling it was low), and now it does it every time I add a little fluid.

To me if it was an overfull problem it would have started when I put the 1 tons in several months before FSI but maybe I didn't have enough sustained driving before then to build the heat like the Utah trip? Does anyone else have a problem with their 14 bolt puking fluid like mine? My axle is clocked up to point at the t case but I fill it properly not up to the fill plug.

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Nice work. I've seen some with foaming issues with the pinion up high like that. Some do it some don't. Mine is up high like yours for the same reason, but I run the level a little below the fill plug to avoid it.

I don't remember what you have in yours for a traction device. My buddy had an issue with the Detroit in his. Only on long highway runs would it puke out the vent. Went round and round, rebuilt with all new bearings and gearset, still did it. His pinion wasn't as high either. Only thing he didn't change was the Detroit. Was it the issue, not sure. Probably contributed to it. He started over with a new housing and an ARB instead of a Detroit.
 
Nice work. I've seen some with foaming issues with the pinion up high like that. Some do it some don't. Mine is up high like yours for the same reason, but I run the level a little below the fill plug to avoid it.

I don't remember what you have in yours for a traction device. My buddy had an issue with the Detroit in his. Only on long highway runs would it puke out the vent. Went round and round, rebuilt with all new bearings and gearset, still did it. His pinion wasn't as high either. Only thing he didn't change was the Detroit. Was it the issue, not sure. Probably contributed to it. He started over with a new housing and an ARB instead of a Detroit.

I have a Detroit in the rear of mine as well and I run the fluid below the fill plug just like you suggest. Maybe I still am a little full with my fluid...

I am just going to power wash all the crap off and then throw a Gatorade bottle or something on the breather for the way down to BB. That will have to do until I can take a better look at it.

Current big ticket items still to finish:
- Radiator w/ E fans
- Rear bumper
- New Driver side rear rim to replace the out of concentric current one. (Rim is already on order, will be here this week).
 
We weren't certain it was the Detroit but when everything except that and the housing changed and it still did it we kinda had an moment of pause.

But like you've noted it took long highway runs for it to develop. Not sure if the Detroit locking and unlocking under load/no load was causing it or what. His housing could have been tweaked or the gears set a little too tight. Wear pattern wasn't bad when it came apart. So he started over with a van width housing and stuffed an ARB in it with all new parts. No more venting.
 
We weren't certain it was the Detroit but when everything except that and the housing changed and it still did it we kinda had an moment of pause.

But like you've noted it took long highway runs for it to develop. Not sure if the Detroit locking and unlocking under load/no load was causing it or what. His housing could have been tweaked or the gears set a little too tight. Wear pattern wasn't bad when it came apart. So he started over with a van width housing and stuffed an ARB in it with all new parts. No more venting.

I believe you are referring to Larry and his K10. I remember reading about his troubles a long time ago but didn't remember until just now. I will just have to perform my aforementioned temporary "fix" and address the issue more seriously at a later date.

I'm exactly 1 month out from Moab and I am already itching to get back into 4 low again...
 
I believe you are referring to Larry and his K10. I remember reading about his troubles a long time ago but didn't remember until just now. I will just have to perform my aforementioned temporary "fix" and address the issue more seriously at a later date.

I'm exactly 1 month out from Moab and I am already itching to get back into 4 low again...
Yep that's the guy. Sometimes they will find their own level, but by having a catch can you can see really how much you lost. Don't want to run it too low.
 
Rear Bumper Complete

Rear bumper specs (A lot like the front):
- Main tube is 2x6 .25 wall
- Frame attachments are 1/2"x 4" strap
- Clevis mounts are from RuffStuff
- Filler plates are cut down 3" x 3/16" strap
- Bolts on with 8- 7/16" Grade 8 bolts. Used two stock front holes per side and we drilled the back two on each side.
- Inner kickers are 1" x 3/16" wall square tube.

Yes it is probably overkill. Yes, I can list about 40 ways I could have done it better.

Gas tank skid and rear bumper are both just fizz can now but after BB I will pull both and get them powdercoated. Hopefully Bertha is running at that time to so I have something to drive. Follow that build here: https://ck5.com/forums/builds/bertha-the-daily-driver-weekend-camper-1991-v2500-gmc.581/

Some in progress/completed pics:
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If it looks very close to the tailgate hinge in the picture thats because it is. Don't have time to fix it now but it will get addressed later. Butch is due for new body mounts and I can die grinder the holes to drop it a little. Ideally when the cage goes in I will be severely limiting my frame/body flex. Obviously that is not happening before BB but it is in the plans eventually.
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These grinder markers really annoy me. It will get addressed before powdercoat.
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BBC Rad w/ E fans Complete

On some long drives at 80+ mph in 85+ degree heat, temps steadily climb with no indication of stopping until I quite driving. Highest I saw was 225 water temp with 230 trans. I know its not that bad but that was w/ 80 mph air on flat ground. Knowing the temps in Moab will be a lot higher than what we saw at FSI I was worried what slow speed crawling temps I would see. So I decided to (overkill) upgrade w/ Cu730 radiator, SPAL 1700 cfm fans (PN 30102044), Tejas steelworks fan shroud, LMC BBC cushions/top plate, and Jabin Wood's hi/lo 3 relay fan harness.

Everything is a bolt in affair and looks pretty slick IMO. Jabin puts Metri-pack 630 connectors on for the fans but SPAL installs some pathetic white plastic non sealed pieces of junk that seriously do not reflect the quality of a $150 fan. I messaged Jabin and he is sending me the proper 630 connectors to finish it up. Don't mind the wiring mess as it still needs to be cleaned up with powerbraid, the proper connectors, zip ties, and I need to connect my AC activation wire.

Overview on Jabin's harness for those that are wondering: He utilizes 3 relays to perform some voodoo magic so essentially my Holley fan #1 setting now initiates both fans on low speed, fan #2 clicks both to high for when you need all the marbles. He then adds a ground activated AC wire so when your compressor kicks on both fans get defaulted to high speed and maintain your airflow over the condenser. For you fast thinkers yes the compressor on Squarebodies is 12+ activated so another relay had to be installed by me (the not so good looking relay to the side) so when the clutch activation sees 12+ it will activate the relay and complete the ground for Jabin's relays.

The real test will be BB and the trip down but the small amount I have driven it since the upgrade I have yet to have the 2nd fan kick on. I also have only had the 1st fan click on when going around town and sitting at stoplights. 80+ mph and temps are stable, no fans on. Maybe I will get better mileage!? Probably not, but I can dream.

On with the pictures:

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Week to go dude... Just saying. :whistle:
Getting excited for sure. It will be awesome to meet a bunch of people and do some wheeling. School literally just started back up for me so I am skipping some classes to go down. Nothing important happens in the 2nd week...
Whats left to do:
- AC activation wire
- Redneck catch can (Gatorade bottle) on 14 bolt breather
- Finish tailpipe
- Oil change
- Give everything a once over
- Hit the road! 18hr drive FTW
 
Getting excited for sure. It will be awesome to meet a bunch of people and do some wheeling. School literally just started back up for me so I am skipping some classes to go down. Nothing important happens in the 2nd week...
Whats left to do:
- AC activation wire
- Redneck catch can (Gatorade bottle) on 14 bolt breather
- Finish tailpipe
- Oil change
- Give everything a once over
- Hit the road! 18hr drive FTW
Excitement is building for sure. 1 week exactly to when we take off. Are you rolling in Thursday?
 
Excitement is building for sure. 1 week exactly to when we take off. Are you rolling in Thursday?
Yeah barring any problems we will be in Moab Thursday night. Probably won't be until late though. Its looking like I am going to wait until my Wednesday classes are over and then beat it down in 1 1/2 days.
 
BB2019 Recap Pt.1

Well its been over for a bit but figured it was finally time to recap my trip to Blazer Bash 2019. Over all a very fun trip and glad I made it down to meet a lot of you guys in person. Also got to see some well built rigs in person that I definitely will pull ideas from for the progression of Butch.

The trip down was relatively uneventful as we only stopped once when my 14 bolt was spitting fluid again. Stuffed the breather hose in a water bottle, zip tied it to the axle and kept going. Picture below of the amount of fluid it spit after adding the bottle for the rest of the trip down and back. Still has me stumped. Anways, cruise set to 82, AC on, one finger on the steering wheel, and 1 1/2 days later we pulled into Moab a little tired but excited none the less.

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Hells revenge was the trail I chose for the first day and it lived up to the hype! I had kept hearing that Hells Revenge was THE trail to run in Moab so I had high expectations. Lots of amazing views, cool scenery, and some decent obstacles to play on. I elected not to run Hells Gate but looking back now I wish I would have. It was fun watching everybody else though. I also enjoyed seeing Rob and Ron the twin campers bobble along this trail as it showed what a house can do as well!

Ran the entire trail without issue (so I thought) except for some pucker factor on what should have been a regular ledge drop down. I was trying to go left but the front end just wasn't pulling over like I needed it. So I had to go right which dropped the right rear in a deep hole and needless to say I gave @Capt Ron and @Bent77 a good showing of Butch's ass when I pulled the left rear tire 4-5 feet in the air. Neither of them got pictures though! I felt it come up and just let go of the brakes cuz I knew it was going over otherwise.

Now we got off the trail and went to unlock the front hubs and I had no issue but dad was like something doesn't feel right over here. I came over and tried it as well and it just wouldn't "click" or "clunk" like it normally does when it unlocks. So we left it engaged and pulled that hub off when we got back to camp. Upon quick inspection everything looked alright but then dad poked the end of the stub shaft as I was watching yokes inside the knuckle. The yokes did not move but the stub shaft was moving a lot. Crap.

Pulled the big snap ring for the inner locking hub assembly and pulled the end of the stub shaft out with the assembly. It fractured the stub right at the splines into several small pieces and shoved the end of it outward so I couldn't unlock the hub. We beat the stub shaft piece out so I could put it together enough to go find parts. Every auto parts store in town didn't have anything but a quick call to Dixie 4wd netted good news. They had a new stub shaft... Problem was it was 35 spline... 1 step forward two steps back... He also said he had another stub and some Warn 35 spline hubs if I needed them.

He said he would check to see if he had a buddy that had a 30 spline for me and get back to me. So we ran to the BBQ and talked to some guys there, and then Stephen/Chris to see if they had anything with them. They unfortunately only had 35 spline stuff as well but no hubs. So right before the BBQ started we ran to Dixie and picked up the Warn hubs and two stub shafts. I was only going to buy one but then he took 50 bucks of the shafts which is way better than I could do anywhere else so two it is. Now with parts in hand and a plan to fix we stopped by O Reilly's and got a ball joint press figuring we would make it easier on ourselves...

After the BBQ back at camp we got to work and got it done as fast as we could as we were both tired. The ball joint press idea turned out to be an exercise of futility as a Dana 60 yoke is too big to push the cap through the receiver and if you use the larger receiver deals then it doesn't have a deep enough throat. Crap! So we switched to the mini sledge and block of wood to get it apart. We did end up using the larger cups from the ball joint press so as not to wreck my sockets. In the end we had it all buttoned up in about 1 hour. We didn't think that was too bad for crawling around on the ground with inadequate tools.

Pics of the breakage and added 35 spline beef...

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BB2019 Recap Pt.1

Well its been over for a bit but figured it was finally time to recap my trip to Blazer Bash 2019. Over all a very fun trip and glad I made it down to meet a lot of you guys in person. Also got to see some well built rigs in person that I definitely will pull ideas from for the progression of Butch.

The trip down was relatively uneventful as we only stopped once when my 14 bolt was spitting fluid again. Stuffed the breather hose in a water bottle, zip tied it to the axle and kept going. Picture below of the amount of fluid it spit after adding the bottle for the rest of the trip down and back. Still has me stumped. Anways, cruise set to 82, AC on, one finger on the steering wheel, and 1 1/2 days later we pulled into Moab a little tired but excited none the less.

View attachment 315736

Hells revenge was the trail I chose for the first day and it lived up to the hype! I had kept hearing that Hells Revenge was THE trail to run in Moab so I had high expectations. Lots of amazing views, cool scenery, and some decent obstacles to play on. I elected not to run Hells Gate but looking back now I wish I would have. It was fun watching everybody else though. I also enjoyed seeing Rob and Ron the twin campers bobble along this trail as it showed what a house can do as well!

Ran the entire trail without issue (so I thought) except for some pucker factor on what should have been a regular ledge drop down. I was trying to go left but the front end just wasn't pulling over like I needed it. So I had to go right which dropped the right rear in a deep hole and needless to say I gave @Capt Ron and @Bent77 a good showing of Butch's ass when I pulled the left rear tire 4-5 feet in the air. Neither of them got pictures though! I felt it come up and just let go of the brakes cuz I knew it was going over otherwise.

Now we got off the trail and went to unlock the front hubs and I had no issue but dad was like something doesn't feel right over here. I came over and tried it as well and it just wouldn't "click" or "clunk" like it normally does when it unlocks. So we left it engaged and pulled that hub off when we got back to camp. Upon quick inspection everything looked alright but then dad poked the end of the stub shaft as I was watching yokes inside the knuckle. The yokes did not move but the stub shaft was moving a lot. Crap.

Pulled the big snap ring for the inner locking hub assembly and pulled the end of the stub shaft out with the assembly. It fractured the stub right at the splines into several small pieces and shoved the end of it outward so I couldn't unlock the hub. We beat the stub shaft piece out so I could put it together enough to go find parts. Every auto parts store in town didn't have anything but a quick call to Dixie 4wd netted good news. They had a new stub shaft... Problem was it was 35 spline... 1 step forward two steps back... He also said he had another stub and some Warn 35 spline hubs if I needed them.

He said he would check to see if he had a buddy that had a 30 spline for me and get back to me. So we ran to the BBQ and talked to some guys there, and then Stephen/Chris to see if they had anything with them. They unfortunately only had 35 spline stuff as well but no hubs. So right before the BBQ started we ran to Dixie and picked up the Warn hubs and two stub shafts. I was only going to buy one but then he took 50 bucks of the shafts which is way better than I could do anywhere else so two it is. Now with parts in hand and a plan to fix we stopped by O Reilly's and got a ball joint press figuring we would make it easier on ourselves...

After the BBQ back at camp we got to work and got it done as fast as we could as we were both tired. The ball joint press idea turned out to be an exercise of futility as a Dana 60 yoke is too big to push the cap through the receiver and if you use the larger receiver deals then it doesn't have a deep enough throat. Crap! So we switched to the mini sledge and block of wood to get it apart. We did end up using the larger cups from the ball joint press so as not to wreck my sockets. In the end we had it all buttoned up in about 1 hour. We didn't think that was too bad for crawling around on the ground with inadequate tools.

Pics of the breakage and added 35 spline beef...

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We had fun

Wish I had a pic of you and Ron coming down that section. You definitely was advertising some tail...
 
BB2019 Recap Pt.1

Well its been over for a bit but figured it was finally time to recap my trip to Blazer Bash 2019. Over all a very fun trip and glad I made it down to meet a lot of you guys in person. Also got to see some well built rigs in person that I definitely will pull ideas from for the progression of Butch.

The trip down was relatively uneventful as we only stopped once when my 14 bolt was spitting fluid again. Stuffed the breather hose in a water bottle, zip tied it to the axle and kept going. Picture below of the amount of fluid it spit after adding the bottle for the rest of the trip down and back. Still has me stumped. Anways, cruise set to 82, AC on, one finger on the steering wheel, and 1 1/2 days later we pulled into Moab a little tired but excited none the less.

View attachment 315736

Hells revenge was the trail I chose for the first day and it lived up to the hype! I had kept hearing that Hells Revenge was THE trail to run in Moab so I had high expectations. Lots of amazing views, cool scenery, and some decent obstacles to play on. I elected not to run Hells Gate but looking back now I wish I would have. It was fun watching everybody else though. I also enjoyed seeing Rob and Ron the twin campers bobble along this trail as it showed what a house can do as well!

Ran the entire trail without issue (so I thought) except for some pucker factor on what should have been a regular ledge drop down. I was trying to go left but the front end just wasn't pulling over like I needed it. So I had to go right which dropped the right rear in a deep hole and needless to say I gave @Capt Ron and @Bent77 a good showing of Butch's ass when I pulled the left rear tire 4-5 feet in the air. Neither of them got pictures though! I felt it come up and just let go of the brakes cuz I knew it was going over otherwise.

Now we got off the trail and went to unlock the front hubs and I had no issue but dad was like something doesn't feel right over here. I came over and tried it as well and it just wouldn't "click" or "clunk" like it normally does when it unlocks. So we left it engaged and pulled that hub off when we got back to camp. Upon quick inspection everything looked alright but then dad poked the end of the stub shaft as I was watching yokes inside the knuckle. The yokes did not move but the stub shaft was moving a lot. Crap.

Pulled the big snap ring for the inner locking hub assembly and pulled the end of the stub shaft out with the assembly. It fractured the stub right at the splines into several small pieces and shoved the end of it outward so I couldn't unlock the hub. We beat the stub shaft piece out so I could put it together enough to go find parts. Every auto parts store in town didn't have anything but a quick call to Dixie 4wd netted good news. They had a new stub shaft... Problem was it was 35 spline... 1 step forward two steps back... He also said he had another stub and some Warn 35 spline hubs if I needed them.

He said he would check to see if he had a buddy that had a 30 spline for me and get back to me. So we ran to the BBQ and talked to some guys there, and then Stephen/Chris to see if they had anything with them. They unfortunately only had 35 spline stuff as well but no hubs. So right before the BBQ started we ran to Dixie and picked up the Warn hubs and two stub shafts. I was only going to buy one but then he took 50 bucks of the shafts which is way better than I could do anywhere else so two it is. Now with parts in hand and a plan to fix we stopped by O Reilly's and got a ball joint press figuring we would make it easier on ourselves...

After the BBQ back at camp we got to work and got it done as fast as we could as we were both tired. The ball joint press idea turned out to be an exercise of futility as a Dana 60 yoke is too big to push the cap through the receiver and if you use the larger receiver deals then it doesn't have a deep enough throat. Crap! So we switched to the mini sledge and block of wood to get it apart. We did end up using the larger cups from the ball joint press so as not to wreck my sockets. In the end we had it all buttoned up in about 1 hour. We didn't think that was too bad for crawling around on the ground with inadequate tools.

Pics of the breakage and added 35 spline beef...

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Not sure why your pictures didn’t post
 
I knew I should have slapped one of my GoPros on the front of Ron's truck! Dang it!

Good recap of the trip. It was great wheeling with you and your Dad. Good times.
 
I knew I should have slapped one of my GoPros on the front of Ron's truck! Dang it!

Good recap of the trip. It was great wheeling with you and your Dad. Good times.
I needed a GoPro on my hat. I was busy pointing and spotting while holding my mouth trying not to scream watching them on a few sections

That one rock pitched both these guys sideways and made it fun. Pretty sure Ian laughed at me center punching the rock with the front diff that stops us cold

We made the descent an adventure on Friday
 
BB2019 Recap Pt. 2

Well something else that had started since getting off the trail Friday was the 700r4 was shifting incredibly hard and/or wasn't shifting at all. The 1-2 shift was barking both rear tires at 10 mph with almost no throttle input. After fixing the stub shaft Friday night we figured we should look at it a bit. Well a quick inspection of the undercarriage showed us ATF everywhere. It was coating the entire tunnel, transfer case, front driveshaft, etc. My front input seal to the transmission had been weeping since the transmission was put in but never enough to really worry about it but it appears as though it let go entirely. ATF was dripping out of the drain hole of the dust cover. Well we checked the dipstick and sure enough it was like 2 quarts low. So we run to the gas station at midnight and buy 4 quarts of ATF, 2 to go in right away and 2 more to carry. That brought the fluid level up on the stick but the shifting did not improve.

While we were on the trail Friday the radiator/e fans performed excellently. The low setting fans ran pretty much continuously keeping the engine temp at about 200-205 and on the really steep climbs or slow on the brakes crawling the high setting would kick on and quickly pull it back down if it climbed to 210. Unfortunately I do not have an auxiliary transmission cooler and only am utilizing the cooler in the radiator. I figured that would be enough but on the trail we saw 230-240 several times. While not insanely hot I will be installing some sort of aux cooler when the transmission goes back in.

Back to the fixing... More fluid didn't fix it but it was up on the stick, we still had all 4 gears, and the fluid wasn't burnt. It was just shifting insanely hard or at higher than normal speeds/rpms So we decided to look at it the next morning after it cooled down.

We headed out to the Flat Iron Mesa meetup and on the way there it was still shifting hard but slightly better than the night before. Upon getting there my dad called the local tranny guy in Fargo to see what his thoughts are as he is the guru for us for 700r4s. Right away he didn't know for sure what the cause would be for sure but he gave us a trick to try figuring there was junk in the throttle valve body. Apparently if you have it running and in reverse you can reset the TV valve by pulling on the TV cable 8-10 times and letting it snap back. So we did it in the parking lot and based off what the transmission guy said it might have helped. Upon leaving for the trail the shifting was back to just about normal.

All gears were there and it shifted at the points it normally does before it started acting up so hurray we thought we fixed it. Well it worked well until about halfway through the day when it started shifting really hard even while in 4wd going from 1st to 2nd. So we elected to get off at the halfway point where the road cut through the trail and head back with Jesse, Rob and Ron. On the way back it shifted alright but steadily getting back to the way it was before with shifting hard.

When back to camp we check the fluid level again and now it all of a sudden is saying the transmission is over full by like 2 quarts... WTF. We have no idea what to think and decide to just do the TV cable trick again and keep an eye on the fluid. We spent the rest of the day researching what it could be and not really coming up with anything concrete. So we just checked everything over and prepared for the trail/trip home on Sunday.

Well Sunday morning I was exceedingly concerned about being able to make it the 1400 miles home with an already hurt transmission let along wheeling another whole trail today. So we stopped by at the meet up point and let them know we weren't attending and headed out. Transmission still acting up a little bit but everything checked out fine. I figured we just needed to make it home so that I can check into it more seriously here.

Made it home essentially without issue but when coming through Colorado climbing up to the Eisenhower tunnel we had some trouble getting up there. In April on the way back when we went through it all I had to do was pull it down to 3rd and set the cruise to 60 and we did it without issue. This time we barely could hold 50 mph and my 250 degree tranny temp gauge is pegged the entire time. Coasting down the other side brought it down a little bit but we decided to stop for a bit especially considering the stop and go traffic we were in.

After letting it cool down it seemed alright so we checked fluid level again (still said overfull) and kept going. For the rest of the trip home we never saw above 180-185 degrees. That was a good thing but by the time we pulled back into the driveway the tranny is shifting terribly again. At this point I know the transmission needs at least a seal in the front and it is hurt in some way. So I will be pulling it soon to see what is in the pan or what else I can find.

Upon reinstalling it will be getting a new TV cable in case this one is frayed, aux cooler, and new seals. I pondered the 4l80e swap now but affording that modification is a little ways off. 700r4 will have to do until then.

This was long winded but here are some pics... Some pictures of the undercarriage ATF/dirt mixture, some pictures of the top of the hill on Flat Iron Mesa, and some pics stolen from Jesse's drop box that he got of me.

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I needed a GoPro on my hat. I was busy pointing and spotting while holding my mouth trying not to scream watching them on a few sections

That one rock pitched both these guys sideways and made it fun. Pretty sure Ian laughed at me center punching the rock with the front diff that stops us cold

We made the descent an adventure on Friday
I have seen videos of people hitting the front diff before... But seeing it in person... And as hard as you hit it... Yeah I was giggling pretty good.
 
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