I'm thinking I might try that evaporust idea and an wire brush. Thanks for the suggestion. As I was thinking on it more yesterday some of that rust on the 14B gears would likely come off "good enough" with just the wire brush and some sort of solvent. On Friday I told my foreman some of things I had planned (blast the axles and gears, what surfaces to protect, etc.), so I guess tomorrow I'll find out how ambitious they got over the weekend. Hopefully they were too busy with the other work we have on the yard to get started blasting the gears!
I'm going back and forth on the front locker idea. Grizzly has a $55 mail in rebate right now (through 9/16), and autoanything.com has an additional 10% off right now as well. Brings the D60 Grizzly locker down to about $550. Then, of course, I start thinking maybe just leave the front open and spend that $ on something like new tires since the BFG A/T's are just convenient since I had them laying around, but they aren't exactly what I wanted to run on this truck. Guess I better not ponder too long since the rebate on the Grizzly ends soon.