CoWj Build /I'm back

Nice...that tilting slide for the fridge is pretty slick. Is that an arb tent enclosure for the canopy?...how do you like it?
I love the ARB Deluxe room, it is my main tent and on my Jeep it was 6' headroom, so I have about a 6'x6'x6' area to use for sleeping or working or anything. I like it for mountain biking because I can put my bike into the tent while I sleep or if I am away on a hike. It's a quick set up one you learn how to so done to about 7-8 minutes for the awning and tent combined.

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Ok well I have been quite busy with the Regear and well we managed to finish. It was a huge project but we learned and made our way through it to the finish. It took about 2.5 days for the rear end. And a day for the front as we did it after the rear.
The Dana 44A actually was converted to a JK Rubicon ring and pinion. We worked a couple 10-12 hour days just trying to learn how the pinion depth and backlash event each other as well as the pattern. Well we probably had the carrier in and out of the housing, 30 times in the end. We learned that the shims enjoy falling out of place and getting crushed by the carrier.
The 44A is a externally shimmed axle as well as the Dana 30 in the wj.
The Dana 44A ended with a almost perfect pattern easily acceptable by any chat and anyone we ask in the industry. ( We talked with Revolution multiple times during the install and they were super helpful and answering any questions we had.)
Here is how the 44A ended up.
Backlash of .0075" which is perfect in the .006"-.010" range.
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The Dana 30 really through us for a loop as the pinion didn't have any shims other than the oil slinger. After talking to some people and looking it up on the answer machine and figure out that we should leave the oil slinger as is and see what comes from it. After a few hours of messing with the backlash and ended up getting a very good pattern and .007" backlash which is perfect as well. 0102191935.jpg0102191935a.jpg
The Dana 30 now has, TJ 4.56 Gears, factory Vari-Lok, New Bearings on the Carrier, New pinion Bearings, inner axle seals, and a new pinion seal.
The Dana 44A has, JK Rubicon 4.56 Gears, still has the ARB, New bearings on the Carrier, pinion bearings, pinion seals, and a JK 1310 yoke.
Now I have to break in the gears and bearings by repeatedly heating and cooling them by driving them for 20ish minutes at a time then letting them cool down for a couple hours. Rinse and repeat for a good 400-500 miles. Then change all fluids. And do a visual check on everything.

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Ok well I have been quite busy with the Regear and well we managed to finish. It was a huge project but we learned and made our way through it to the finish. It took about 2.5 days for the rear end. And a day for the front as we did it after the rear.
The Dana 44A actually was converted to a JK Rubicon ring and pinion. We worked a couple 10-12 hour days just trying to learn how the pinion depth and backlash event each other as well as the pattern. Well we probably had the carrier in and out of the housing, 30 times in the end. We learned that the shims enjoy falling out of place and getting crushed by the carrier.
The 44A is a externally shimmed axle as well as the Dana 30 in the wj.
The Dana 44A ended with a almost perfect pattern easily acceptable by any chat and anyone we ask in the industry. ( We talked with Revolution multiple times during the install and they were super helpful and answering any questions we had.)
Here is how the 44A ended up.
Backlash of .0075" which is perfect in the .006"-.010" range.
The Dana 30 really through us for a loop as the pinion didn't have any shims other than the oil slinger. After talking to some people and looking it up on the answer machine and figure out that we should leave the oil slinger as is and see what comes from it. After a few hours of messing with the backlash and ended up getting a very good pattern and .007" backlash which is perfect as well.
The Dana 30 now has, TJ 4.56 Gears, factory Vari-Lok, New Bearings on the Carrier, New pinion Bearings, inner axle seals, and a new pinion seal.
The Dana 44A has, JK Rubicon 4.56 Gears, still has the ARB, New bearings on the Carrier, pinion bearings, pinion seals, and a JK 1310 yoke.
Now I have to break in the gears and bearings by repeatedly heating and cooling them by driving them for 20ish minutes at a time then letting them cool down for a couple hours. Rinse and repeat for a good 400-500 miles. Then change all fluids. And do a visual check on everything.

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Nice work! Bet your glad to be past that mod.
 
Nice work! Bet your glad to be past that mod.
I am however as difficult and time consuming as it was. I enjoy learning the new skill with my boss. But We did learn that there are a lot of people out there that have done one or two regears and claim to be experts. Especially on the internet, so it is sometimes hard to find correct information without calling someone that does gears for a living.

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Regear Update. I have driven about 1500 miles on them, including returning back to my home of Gunnison, around the area of vehicle recoveries (coming soon, recently did #9 on my school year) and to Moab for camping and hiking last weekend.
First thing that I notice. On the front range the gears seemed to be Overkill because driving around there and in town there is not much strain on anything. However driving back to 8000' elevation in a town that required multiple mountain passes to get to. It makes a world of difference. The Jeep used to struggle on Cerro pass and normally would end up being in 2nd gear (HI second for the 545rfe nerds out there) going 45 in the slow lane up at 3000rpm. Which was not idea.
Now I can hold 65 up it in 4th gear at 2700rpm all day without any issue and on super steep pitches I can easily do 55 in 3rd at 3200.
I have noticed that in driving to Moab, the Jeep started to get a really bad vibration at 70+mph. I believe I have traced it to the front driveshaft as it is the original driveshaft which is likely a couple inches to short for the lift and the cross member lift. So I have a new one on order and it should arrive today and I will get an alignment and have them adjust the caster to see if that is also part of the issue. Hopefully this will solve it and then the Jeep will be pretty dialed with the new gears and radiator.

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My latest recoveries are 2 cars and a diesel truck.
On MLK day Gunnison got a small snow storm. Not even an inch but because it had been around 10° on the highs and -20° as the lows. All the snow that hit the ground turned into a sheet of ice on highway 50. I got a call from another student saying that their significant other was off the side of the highway and needs a tow. As I was on my way out there we got word that a Park Service Range was attempting to get them out but I know that do to some legal reasons they are not allowed to pull with there vehicle without special permission. He was attempting to use Maxtrax to get the vehicle out with no luck. When I arrived there was another car in the ditch on the same turn of the highway. And this turn is a perfect storm for cars to go off. It's a fast 60+mph turn (when dry) that is downhill and off camber towards the inside of the turn. Likely the first car (grey sedan) was coming around the turn, the tail started to slide and the driver panicked and hit the brakes causing the rear to come all the way around and go nose first into the ditch 90° to the road.

The second vehicle Subaru WRX likely saw the police lights off the Park Ranger hit the brakes and spun of into the ditch just not nearly as far off the road.

When I got there and was walking around the scene, and talking to the Park Ranger (how handed the scene off to me because I was there and knew what I was doing to get the road open faster than calling multiple tow trucks and dealing with them taking a couple hours to get there. Everyone was having trouble just simply walking on the road because it was a half inch of snow covered in a layer of ice. No plows had been by and there was no gravel or anything on the road. So my first idea was to out chains on. I put all 4 tires chains on to get any sort of grip on the ice and without them I doubt I could have done the recovery.

It was about this time when the State Trooper showed up. In which I explained what my plan was and he gave me the option of being able to fully shut down that section of highway for a couple minutes to get the cars off. Which was so cool to have that permission.

The WRX was just a little bit of the road, but the front tires were slightly off the ground, just enough that it couldn't get traction to back out of the ditch. Luckily he knew exactly where the tow pin was and I know that they are just big enough to fit the pin of a D-Ring through. My plan was to just use low range and give him a just slow tug out of the ditch. I still had a tiny bit of tires soon even with the chains, but one they dug into the pavement under the snow the Jeep pulled the WRX out at 1000rpm nice and slowly. So he was back on his way nice and quickly.
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Unfortunately my recoveries are not usually picture heavy as I am usually just focused on getting it done quickly.
The second vehicle was much deeper in the snow and thanks to Chrysler's cheapness in the 90s this sedan didn't have a single tow point on it anywhere. A gentleman who was helping me and I looked for a good 20 minutes and found nothing under underneath it. So they next option was to find the strongest point to be able to pull off with the lowest change of vehicle damage. This ended up being the rear subframe in between where the suspension components attach to.
I definitely knew that the winch was by far the best option for this recovery as I needed as much control to get this car to pivot up and out of the snow as it was bellied out.
View attachment 320115received_2277576939183215.jpegreceived_824049441320329.jpeg
With the winch I was able to get it to come out nice and slowly without much drama. Once it was out the driver got a taking to be the local state trooper and a warning that if they ever came back up to Gunnison again they better have snow tires and not cheap bald summer tires. He also gave me permission to escort the driver back to Gunnison until the road unfroze the next day.
It was not my most difficult recoveries but due to only being able to close of the highway for short amounts of time. I had to make sure that everything was as set up as possible before I closed it down to pull.
It was also one of the colder recoveries as it was -15° one the sun went down and being on Blue Mesa Reservoir we had winds up to 20-30mph for most of the recovery.
In the end I was there for an hours and 45 minutes. And not a single plow truck ever came by so the state trooper had some choice words to the head of CDOT on the phone during the recovery.

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A few days later, I was itching to get out camping and I had a friend in Fairplay having the same issue. So we said screw it and decided to head out to Moab for a weekend of camping and hiking, due to recent snow the trails in the area we're very muddy and not wanting to cause damage to them we decided not to go wheeling.
I left at 2pm on Friday and he had left earlier that day because he had to stop in at a near by dealer for a service on his tundra.
About 30 minutes outside of town on highway 50, one turn past where I had been recovering vehicles on the highway. I spotted out of the corner of my eye a truck that looked like it was sitting a little funky. It was off on a side dirt that get no winter maintenance, which for many locals here isn't an issue as most have 4wd and good tires. But it looked like it was sitting on the side of the road and tilted as if it was in a hole or ditch. So I turned around at the next possible spot and sure enough. He was stuck

It was a Ram 2500 Cummins, lifted on 35s or 37s as I pull off the highway and onto the dirt/snow road, I could see he was cross axled out in a ditch and stuck.
So I grabbed my gloves and coat and hopped out to offer him some help. At first he was a bit apprehensive about my small Jeep pulling out his large truck, but he eventually came around and agreed that anything was helpful. Luck for me his truck was only maybe sitting on the front axle but mainly just open diffs and crossed up so it had no traction on the ice and snow. He said he was going up to a field only about a mile up the road to let his dogs run in the snow in which we had about 19" on the ground.
I new that I was gonna winch him, I knew that maybe I could have done a slow dead pull but I had no reason to since it's so easy to pull with a winch. With some quick instructions to the driver about just keep the rpm low while I pull we started trying to remove the big ram from the ditch. Unfortunately the issue came from him, as he would start to climb up an out of the snow bank he would give it too much gas, the turbos would light off and he would spin and slide back into the ditch. Eventually after a could pulls he figured it out and after 20 minutes he was out and on his way again. He was very impressed at the pulling power on the warn Zeon winch and say that was the next thing that he was gonna do to his truck.
He was very proud of his truck nonetheless, it was a fully built Cummins motor, built trans, geared and chromoly axleshafts, but no lockers which was why he got stuck.
No matter how much power you have, you only have enough for how much traction you have.0125191512a.jpg0125191520a.jpg

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The rest of the drive was very uneventful until I hit i-70, where holy driveshaft vibrations batman! With the new gears the driveshaft are spinning significantly faster. And above 70mph it started to vibrate violently. I was halfway to Moab at this point and under 70 it was extremely smooth with no issues. So I pushed on at 65 down the highway, till I got to Moab where I set up camping around 8pm and my friend made it around 9:30pm.
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I am really loving my current set you for camping
It was his job to bring the firewood, and he did but in the form of giant logs that he had left over from a log cabin build. They were nice pieces of wood and burned very nicely. However neither of us brought a full size axe, we both had hatches which we always keep in the rigs at all times. But when you are trying to split a 20" log it a bit difficult. Luckily I always had a mini 3lb sledge hammer so I just went about using the hatchet as a splitting wedge. 0126190858_HDR.jpgFB_IMG_1548518918031.jpg
The sun rose after a cold but not freezing night, as the lows dropped down to 17° being from Gunnison that was warm for me and I brought my Slumberjack -20 Blizzard bag, which kept me nice and toasty all night even without long underwear which I spaced and forgot at home.
We left my Jeep at camp and took his tundra and made our way to arches national park, except, we took the back 4wd road into the park because it's fun and to access the back of the park it can be faster is you have a capable rig.
Our plan was to hike the fiery furnace but as the government shut down had ended only a few hours before we got there it was still closed. So we settled on devil's garden instead and pushed to do the entire 7.2 mile hike. It was a blast however there was a lot of death ice everywhere.
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Next up was delicate Arch for the sunset in which we speed hiked up as we were running out of time.0126191726.jpg
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And back to camp for a lovely fire as the temperature dropped down below freezing for the night.0126191923_Burst06.jpg

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The next day we had a late start. But decided instead of packing and heading home we made breakfast.
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Packed up camp.
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And headed back into arches, this time the normal way to talk to the rangers and see if fiery furnace would be open, which it wouldn't be for a couple more days so we decided to head for Broken Arch and Sand Dune Arch, a short 3 mile hike but one that neither of us had done.
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Sand Dune is not for those who don't like tight spaces.
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The Arch is pretty neat with how hidden back in the canyon it is.0127191430_HDR.jpg0127191435_HDR.jpg
Next up was Broken Arch which is a mile from Sand Dune Arch, and we found the mud...
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But after a few muddy spots we made it to the Arch0127191447.jpg0127191449_HDR.jpg0127191458a.jpg

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My latest recoveries are 2 cars and a diesel truck.
On MLK day Gunnison got a small snow storm. Not even an inch but because it had been around 10° on the highs and -20° as the lows. All the snow that hit the ground turned into a sheet of ice on highway 50. I got a call from another student saying that their significant other was off the side of the highway and needs a tow. As I was on my way out there we got word that a Park Service Range was attempting to get them out but I know that do to some legal reasons they are not allowed to pull with there vehicle without special permission. He was attempting to use Maxtrax to get the vehicle out with no luck. When I arrived there was another car in the ditch on the same turn of the highway. And this turn is a perfect storm for cars to go off. It's a fast 60+mph turn (when dry) that is downhill and off camber towards the inside of the turn. Likely the first car (grey sedan) was coming around the turn, the tail started to slide and the driver panicked and hit the brakes causing the rear to come all the way around and go nose first into the ditch 90° to the road.

The second vehicle Subaru WRX likely saw the police lights off the Park Ranger hit the brakes and spun of into the ditch just not nearly as far off the road.

When I got there and was walking around the scene, and talking to the Park Ranger (how handed the scene off to me because I was there and knew what I was doing to get the road open faster than calling multiple tow trucks and dealing with them taking a couple hours to get there. Everyone was having trouble just simply walking on the road because it was a half inch of snow covered in a layer of ice. No plows had been by and there was no gravel or anything on the road. So my first idea was to out chains on. I put all 4 tires chains on to get any sort of grip on the ice and without them I doubt I could have done the recovery.

It was about this time when the State Trooper showed up. In which I explained what my plan was and he gave me the option of being able to fully shut down that section of highway for a couple minutes to get the cars off. Which was so cool to have that permission.

The WRX was just a little bit of the road, but the front tires were slightly off the ground, just enough that it couldn't get traction to back out of the ditch. Luckily he knew exactly where the tow pin was and I know that they are just big enough to fit the pin of a D-Ring through. My plan was to just use low range and give him a just slow tug out of the ditch. I still had a tiny bit of tires soon even with the chains, but one they dug into the pavement under the snow the Jeep pulled the WRX out at 1000rpm nice and slowly. So he was back on his way nice and quickly.
View attachment 320114
Unfortunately my recoveries are not usually picture heavy as I am usually just focused on getting it done quickly.
The second vehicle was much deeper in the snow and thanks to Chrysler's cheapness in the 90s this sedan didn't have a single tow point on it anywhere. A gentleman who was helping me and I looked for a good 20 minutes and found nothing under underneath it. So they next option was to find the strongest point to be able to pull off with the lowest change of vehicle damage. This ended up being the rear subframe in between where the suspension components attach to.
I definitely knew that the winch was by far the best option for this recovery as I needed as much control to get this car to pivot up and out of the snow as it was bellied out.
View attachment 320115View attachment 320116View attachment 320117
With the winch I was able to get it to come out nice and slowly without much drama. Once it was out the driver got a taking to be the local state trooper and a warning that if they ever came back up to Gunnison again they better have snow tires and not cheap bald summer tires. He also gave me permission to escort the driver back to Gunnison until the road unfroze the next day.
It was not my most difficult recoveries but due to only being able to close of the highway for short amounts of time. I had to make sure that everything was as set up as possible before I closed it down to pull.
It was also one of the colder recoveries as it was -15° one the sun went down and being on Blue Mesa Reservoir we had winds up to 20-30mph for most of the recovery.
In the end I was there for an hours and 45 minutes. And not a single plow truck ever came by so the state trooper had some choice words to the head of CDOT on the phone during the recovery.

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If you plan on doing a lot of recovery work, some cluster hooks are a good addition to your tool kit. They hook into the small holes in the frame that are for that purpose.

Another method is to use a strap through a wheel.

Great work clearing things up.
 

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If you plan on doing a lot of recovery work, some cluster hooks are a good addition to your tool kit. They hook into the small holes in the frame that are for that purpose.

Another method is to use a strap through a wheel.

Great work clearing things up.
Huh that's super cool I may pick one up to throw in my tool kit. I seem to get called out a lot after a storm so maybe this will help in the future!

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Ran down to the front range for a long weekend of work, doing some R&D and custom install of a ZR2 diesel Dual battery system and many other things. But all of it almost didn't happen due to a major storm that hit Wednesday and Thursday night. On Wednesday night we got 7" of nice fluffy powder which is always a fun experience.0213192104.jpg
0213192129b.jpg I drove around for a little while in the powder for fun, and I am extremely impressed with how well the Falkens hook up. I have around 20k miles on them at this point and they look and feel brand new still. Thursday rolls around and boom we get hit by another 7" however this time, it's super heavy dense wet snow. Of course this fell during the day which was just above freezing before dropping back down nice and cold in late afternoon. So all that wet snow turned start to ice. And came the first recovery of the night around 9pm, as I was driving around I came across a Tj on 32 muddies that had tried to pull out of a parking spot on the side of the road. Well due to the snow and ice it kept sliding down the hill away from the road. With a quick pull on a strap he was up and on the road again. Next was a Range Rover that had driven from Texas all day for a weekend of skiing in CB. With all the wet snow they had been driving through the radiator iced up and the truck went into limp mode on Monarch pass. They slowly made it to the center on Gunnison but upon coming to a stop it died, permanently. Of course it had no tow points on the front. So it was to pushing, I gathered a few locals and we pushed this range Rover out of the middle of the biggest intersection of Gunnison. They got a ride to a hotel and that was that.
I was still waiting to make the call of whether or not I was still gonna try to make the drive back to Longmont, at this time it was still dumping, monarch was closed, and my hope was fading. I awoke on Friday, to sunny blue skies. So I quickly hopped online to check the conditions of Monarch and it was still closed. This time for avalanche mitigation... Oh boy...
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I had a class till 2pm so I was planning on leaving after that if it every opened. Around 1pm I checked again, and found that an avalanche did happen. But on the west side of town near Blue Mesa.
But monarch was open! So off I went, after finishing class I loaded up and headed out excepting some snow off the roads. And they were dry and clear...
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Tons of snow of the road side of Monarch.
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Not nearly as much on Kenosha pass.
Upon making it home after stilling in a bit of Denver and Golden traffic, I went and filled up gas to see what gas mileage the Jeep got with the 4.56 gears. So the total was 230.9 miles and the Jeep used 11.9 gallons, so 19.4mpg!! Which is awesome and it has stupid amounts of power for climbing hills and passed now. Screenshot_2019-02-15-18-21-55.jpg
And what was this waiting for me at the shop???
0216191919_HDR.jpg Question is, what vehicle is this for?

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The drive back was just about normal for this time of year. The usual small amounts of falling snow that get progressively heavier till I get on the west side of Monarch where is returns to just a light flurry.
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Stopped on a dirt road near the summit of Kenosha pass to take some photos of the Jeep in the sun.
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Next was another quick stop in Salida where I had caught up to the snow that was predicted to be all over the mountains and front range.
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The snowfall increased the closer I got to monarch, now starting to have a little dusting of snow on the road.
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Never really covered the road but just had enough snow to make it rather dark out. But other than a few deer running out in front of the Jeep nothing exciting happened on the Pass.
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Lots of snow towards the top of the pass. Probably a good 8-9 feet that the plows had cut through over the past couple storms.
Nothing majority exciting, just a normal drive in the winter of Colorado.

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Made an attempt to get out camping last night to a rather failure of a trip but on the bright side I had a blast just doing a bit of snow wheeling around Salida on the some of the Forest service roads in the area. There was snow ranging from 6" on the main road to over 2 feet of drift snow off on some side roads.
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Nope not making it up to this campsite, this was a 3' drift that the Jeep fell into luckily it backed right out without issue.
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The main road wasn't great but it had been driven unlike all the side roads.
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Well this is where I had camped last time I was here... Don't think it's gonna happen.
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Ok, one last road, and it looked promising, only 8-10" of snow but the actual sites had more drifts up to 3'. I think it was at this point I called it and faced another issue.
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Airing up it gonna be fun... To say the least. I did think about just driving part of the way back to Gunnison without airing up but I had gone down to 14psi and while I would have driven with around 20psi I didn't wanna do it with 14psi.
So it was a rather failed going trip but a great snow wheeling trip. Got some convince back from my last big snow trip, which was back in 2015 when it ended like this.
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Snow like that sucks to drive in, but camping on top of 3 feet of snow is actually really fun. You can level the snow and put a tent anywhere. But without snow shoes, walking around is pretty cumbersome.
 
Snow like that sucks to drive in, but camping on top of 3 feet of snow is actually really fun. You can level the snow and put a tent anywhere. But without snow shoes, walking around is pretty cumbersome.
Yup, I did find a spot that was only 4" deep and really wanted to camp there but I had seen a heard of about 200 elk in the canyon and the area I selected was at the bottom on the canyon where they all go funneled down into a narrow section, and that's right where the tent would have gone. So I didn't really want to wake up surrounded by a heard of elk. Plus they scared me by standing right behind me and when I turned around right on the edge of the tree line there were just hundreds of eyes staring right back at me.

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Next up the front end gets an update finally!
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While I like the look of the Flatlands bumper it honestly was a POS I bent the winch plate up by an inch as well as bent both mounting brackets causing the bumper to shift up and bend the fenders as well. That's what I get for getting the cheap option. Well I learned my lesson.
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ARB Time!! And if you look closely it doesn't have a winch in it! Well I think the Wj ARB is has the smallest possible clearance for a winch. Even with the top mounted solenoid removed it wasn't even close to fitting that Zeon in there. That or the Zeon is a giant winch. I would have had to cut the entire front cross member out but I wasn't willing to do that, so a few phone calls later we installed the bar without a winch. Hoping a late shipment from warn would arrive in Colorado soon and I could grab a 9.5 XP-S as a upgrade.
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Amazingly the Warn shipment that was 12 days late showed up the next morning so after a few shop project a took Burt (My Tacoma) down to Denver and picked up my new ultra badass winch! And it came with a sweet bonus!!! A Warn wireless controller kit just randomly in the box and a sticker on the outside saying one was included!
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I am in love with the new look, so I pulled CoWj inside to pull the bumper off and get the winch in.
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Clocked and loaded.
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Now that is what I call drool worthy...
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Gotta love having a long driveway, on a hill, and with a perfect tension weight to help get the new line spooled in perfectly.
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Really digging the Wireless Remote. Cool addition to the kit.
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Of course I had to get some glamor shots while driving back to Gunnison. Oh and Monarch, yeh it's a breeze now, I can hold 60 up the east side if I want. And with the better cooling design of the ARB it stays perfectly at the normal operating temp.
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Gotta got a photo of MT CB when I was up there for my Birthday. All about the glamour shots with the bumpers right now.



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