Update
Slowly I've been working on the 14bolt. I trimmed the bottom and would not do this kind of trim again. Too much work for so little gain. If I were to shave again I'd do a cut and a plate (ballistic fab has a shave kit) for a reasonable gain. Live and learn, mine's done now so I'll run it. Basically I did an aggressive grind on the lip, closed up two lower holes and replaced them with one.
With heat and welding I attached a long joiner nut on the inside of the housing. This was all measured a bunch of times.
I then had to modify the new diff cover that I got from Ruffstuff to match. After measuring, cutting, grinding and welding it's finished.
The lip needed some more material so that was added and a hole in the right spot was drilled.
With the cover done I cleaned the inside out and set up the pinion and carrier. I kept the factory shim for pinion depth and adjusted the collars for the carrier to get .008" backlash following the pirate4x4.com tech article. I was ready to move on so I got new calipers (I had taken the last set back that looked a little haggard) and test fit all the components. As is turns out I got a set of disc brake brackets that ended up placing the pads 1/4" off the rotor. I talked to Ruffstuff and they're sending out another pair. Those guys have been great to deal with! Plan is to move forward with the swap next week. I've also got my rear driveshaft figured out using the parts I have on hand. The front 8-lug adapters also finally showed up so I'm just about ready to run those beautiful tires sitting in my shop giving it a wonderful new tire aroma whenever I open up the door.
And then just last week Dora had a little mishap.......
I drove to work, parked and turned on the fan to aid in cooling down the turbo (pulling air through the intercooler) and smelled something funny. Turned everything off and popped the hood. Could get a slight wiff of electrial but couldn't see anything so I figured it was fine, shut the hood and went inside. Shortly after going inside I was running back outside grabbing a fire extinguisher on the way out. There was lots of smoke coming up from Dora's hood but I did NOT open the hood, I just unloaded the extinguisher in the cracks in the hood and wheel well. I grabbed some gloves from the back, opened the hood and yanked off smoldering hood insulation and disconnected the battery. The fire department showed up (911 was called per protocol) but I had it out quickly so they verified it was out and just took some info. As I assessed the damage I disconnected all wires associated with the fans.
Damage report:
- Coolant overflow melted
- lids on power steering reservoir and master cylinder melted
- dipstick melted
- pressure hose going to gear box compromised
- silicon coupler on intake compromised
- hood insulation chared
- smoke sticking to multiple places
- TPS restraining device (ruler) melted
Tested batteries with my multimeter-GOOD. Tested TPS signal-GOOD. Needed a new overflow reservoir-water bottle will work-GOOD.
Called my

to come pick me up and we went and had another pressure line made along with picking up more power steering fluid. I replaced the line, double checked everything else and started it up. Only system not working were the fans and I don't absolutely need those if I take it easy so I kept boost under 10psi not to blow my duct tape job on that coupler and made it home without incident. I took the rest of the day off to get to the clean up and further investigation.
ROOT CAUSE: power wires coming out of the spal fan controller were in a protective sheath (came that way) and those shorted, hard to say why but that's where it started and they were just about fused when I tried pulling them apart. Why the fuse on the controller didn't pop I'm not sure.
I pulled the hood off to make it easier to get to stuff and went to town with a scott pad and soft scrub. The hood took the heat damage with the underside loosing paint accompanied by the top showing a small discolored spot in the finish. That spot will probably flake away. For the most part everything cleaned up well. My dipstick was way too long anyways so I shortened that so that's good. I spent a couple hours on Monday at the junkyard looking for overflow tanks and reservoir lids and have replaced the power steering reservoir cap along with the master cylinder caps. I found an overflow tank that slid right onto the same mount (came out of a toyota celica). I put that one on the brown cruiser and grabbed the landcruiser tank since it was a little bigger for Dora. I ordered another silicon coupler for my intake tubing. I ordered another dual fan controller, just not one made by spal. I made a new TPS retainer cover out of aluminum to replace the melted ruler. Since it's a hotter week in the PNW I decided to leave Dora home due to no fans and take the other car. In all I was fortunate there was only minimal damage and it's relatively easy to fix
This gets me up-to-date and I think I'm ready for things to calm down now.