Thanks for all the ideas guys. They have leaned me towards upgrading to 36" or 37" tires and a longarm system. I would like to add a winch and aftermarket bumpers. I guess the only thing I am really hung up on is what axles and their ratios. I know I will have to do away with the D35 but I was considering doing and 8.8 conversion in its place. But since the D30 will only gear to 4.88 will this be enough to pull all of this weight. And how low can an 8.8 be geared.
I guess we're using 1990's definition of 'hardcore'.
What was once considered hardcore isn't anymore. Your standard 1Ton axle swap isn't really that extreme, unless you're stretching it. Funny thing is if you has a 1T Jeep just a few years ago, it would have been hardcore. If you want to see what I mean, check out
http://www.pirate4x4.com and look at what's in the hardcore forums and what's in the Non forums.
In any case, are 37's going to be the limit? Do the trails you plan on going on require some heavy throttle? 37's are considered the limit of the 8.8" and if you're going to be punishing them, you'll probably want to go bigger. A Ford 9", Dana 60 or the Corporate 14 Bolt. Out of those the Corporate 14B will probably be the cheapest. Actually, it might even be cheaper then the 8.8" since that seems to be the go-to axle choice over the D35c. The downside to the 14B is that it's HUGE, but you can shave off 2" fairly easily. The other thing is there is only one carrier with no gear splits so they use thick gears which stop at 5.13:1. Also, locker choices is a bit limited BUT you can get a Detroit for it. Then there's the pluses, it's huge all around. The shafts are huge and you can get them in full-floating configuration which is nice. Drums are HUGE and heavy but there are disc conversions if you care.
If you're on a budget and want a milder build then go with the 36-37's and swap out the Dana 35 with a Ford 8.8". This will allow you to have some money left over to lift and correct for an problems that might arise. You can keep the Dana 30 since strength wise, it's OK if you're not beating on it too badly. The only problem is gearing although when you're in 4Lo, it won't matter as much.
Want more, they the next step would be to go with some SJ Dana 44 axles. This would allow you to gear lower. Still with a heavy foot, and 37's you might want to go bigger. Although a friend has some D44's with alloy shafts, 5:13 gears and runs 38.5"'s with a 4to1 and only breaks U-joints on occasion. It's more about crawling out here. Not as much need for wheel speed.
One more, and you could go with some Dana 44, Ford 9", Dana 60, combo and get 3/4T status. Although I'd probably just go all out at that point and do a Dana 60/70 combo or Dana 60/14B.
