IMHO If you plan on doing any rock crawling
use 3/16" or 1/4" wall thickness material.
I cut my rotted rockers out and built some 2"x2" sliders, looks somewhat stock for my truck at least!I bolted it through the frame(3 plates w/four bolts a piece with sleeves each side) and the bolts also...
The rotor was not quite a bolt on, but close and the center had to be opened up a hair.
The center is not the right size for your d-shaft pilot, plus anytime your d-shaft would need to come off all the e-brake crap would too.
HTH
I used the E-brake rotor and caliper from All Pro on my split case.
I made the mounting plate/bracket.
Make sure you bolt the rotor on the t case side of the companion flange, not sandwiched between them!
The cable has been the biggest issue,I need to get a new one made.
I think mine was converted from 240 to 120 by just using one 120 leg and safely disconnecting the other leg at the breaker.Saves the hassle of running new wires.............
Pro installer did it .....not me
Good Luck!
Don't forget, spring arch and leaves is what gives these wagons the load capacity they need.Too flat(soft) springs and your camping gear w/family will be bottoming out.
You will get 4-6" of lift from a SOA but it won't last.Axle+Spring perch.
My upper(frame) rear shock mount cross member rusted out and I replaced with a 2" piece of tubing.Carefully drill out the old one(a two inch hole saw worked for me).Slide the new one into place and weld it in.Don't forget to drill/sleeve holes for shock mounts.For my long travel shocks I made a...
Funny how it looks round but I used the stock opening as the guide.I'll take a pic of the cut out.I always wanted reuse the stock "flare" but didn't get around to it.
I used a small adjustable square ,a black marker and the plasma torch.
Good Luck!
Here's a better shot of what and why i cut 4 ".I only cut enough to use the inner fender in it's OEM state and then used 20 ga. to tie it all back together.
HTH
You mean like sit there ,drink beer and stare at them sagging?
I think the SOA configuration is really hard on leaf springs that was more or less the point ............I think?