Im not 100% sure why I have a build thread since Im so terrible at taking pictures but I do have an update. Got the scout mostly put together and decided it was time for a shake down run as it hasn't left my property since I put in the dana 60. I think we may have shook it a little too hard as I ended up with a long walk and a long afternoon dragging it out of the woods.
We decided to take on a trail that follows a creek bed that is near our house. This is normally about a 2.5 hr ride if there's no breakage or stops for pics. My wife does have a few waterfall pics Ill try and steal to post up later. Now let this be a lesson to those that like me go for rides alone and if it wasn't for my extensive knowledge of the area and familiarity with hiking it I probably wouldn't go alone but I feel pretty comfortable as I spend the majority of the winter hiking up and down these mountains in search of groceries, a.k.a. Deer. So we packed up tools and spares and ice chest full of water and snacks and set out.
Most of trail went without a hitch but as we made the last creek crossing the front passenger tire slid down the rock ledge and into a v-notch. Upon impact I heard the tale-tale kapow of a broken axle shaft and my first instinct is "wtf, Im running a dana 60 with 35s, this shouldn't happen" but as we progressed I soon realized that the "kapow" came from a little further back. Upon exiting the creek bed the scout ceased all forward movement, the engine revved and the smell of hydraulic fluid filled the air. I crawled out to find what I feared the most. We had to use the winch to drag the scout up out of the way. With no hope of a trail repair, no cell phone service and no help, walking was the only way and since we were at the bottom of the mountain, up was the only direction. My wife did not feel the need for both of us to make the uphill journey and Im much faster by myself so she agreed to stay with the scout while I made the hike.
I grabbed some water from the ice chest and set out on my journey to find cell phone service. As it turns out not only did I have to walk up hill but I had to walk all the way up hill, that is 4.5 miles uphill to the very peak to find cell phone service. I finally reached the top after an hour of vigorous walking and shortly after I made the call for a ride I met some fourwheeler riders that were stopped for a break. I no longer needed a ride, as I now had one coming, so I sat and chatted with them until my ride showed up. We drove back down the hill and picked up my wife and back to the house. As it turns out all my friends with a 4x4 capable of reaching the scout and pulling it out were out of town. To make matters worse, my 85 gmc with one tons and lockers had a bad fuel pump. With no other option I dropped the 3/4 full tank of fuel, installed a new pump and put the tank back in. Hooked up the trailer and away we went.
Had to leave the trailer at the trail head and drive the truck to the scout. Once there right off the bat I had to winch the scout sideways to get it off of a rock that was in the way. My wife drove the scout while I pulled here in my truck stopping ever so often to drag the scout around a tree with the winch. It took us 1.5 hours to go 1/4 of a mile. Once back at the road I hooked back to the trailer and loaded the scout and back to the house. Our 2.5 hour trail ride turned into a 9 hour adventure and on to some carnage pics.
This makes the 4th and final time I have broken this transmission case. #1 was the top corner where the t-case adapter bolts on, caused by loose bolts, #2 was directly in front of #1 but a bigger chunk broke, caused by improper mounting that was too rigid, #3 was the corner of the bellhousing when it bound up during installation, and #4 was the whole tailhousing caused by hard bottoming out of a driveshaft that was too long. All stuff that could have been prevented.
My driveshaft checked fine when testing in the lab but real world conditions but a stress on it that I didn't mimic. Live and learn.
Oh and my new picture taking device should be here tomorrow so the pics should get better.
Every time you take it apart it seems like you get it back together for approximately no dollars. 
I was kinda shocked when you decided to buy the 1-ton axles. That must have more than doubled the cumulative cost of the build. 
