Yet another sas thread... sorry
 

I have searched, and taking a lot of info on blaz's thread and others, BUT.....

I have not found, might have scrolled past sleepingly, info on the smallest lift possible for a function SAS, like running 32s. Will that just depend on keeping the rear axle over, and a "flater" leaf on the front with the axle over as well?

It depends on clearance between the front diff and the frame, oil pan, etc. Just pulling a number out of my butt, though, I would say the minimum is about 6" of lift if you use a Dana 30 front axle and modify or remove the crossmember under the engine.

Thanks, also I've seen people reinforce the axle, is that a must or preference?

I've never re geared an axle. would I be able to regear a zr2 axle to match the front, or opposite? I would be using an xj front, and adapters for the hubs.

As well on any options on best way to wire my transfer case, or is manual easier and better?

If you put a truss on top of the axle, you'll have even less clearance. The D30 is strong enough for "normal" use with smallish tires, but it's not the best choice for big tires, lockers, or serious offroading.

You can regear the rear to match the front, but it's not very easy or cheap.

I personally prefer a manual transfer case, but there's really no good reson not to keep the one you have.

I wont be needing that, not that serious. 6" is a little more then I wanted, but rather have the solid axle then the ifs.

Is regearing doable to the hand tool driveway mechanic? I'll be getting my mechanic to do the fab on the SAS, but any prep work I can do to save money is ideal lol.

If you regear it yourself, you'll need a few "advanced" tools like torque wrenches, a dial indicator, bearing puller or hydraulic press, etc., but it is possible to do in your driveway as long as you have a lot of patience and can follow instructions.

Don check out some of the builds over on the S10 forum. I will say though most people that start out with a Dana 30 and smaller tires end up going bigger lol. I'm getting ready to start gathering parts for a sas myself. Since I put the 35s on my Jimmy I've just been waiting for the stock front end to implode! I have recently started replacing wore out parts with cheap replacements to get me by for now.

Yeah, I tried to avoid that problem by going straight to a Dana 60 and 37s. I'm kinda thinking about 40s now, though.

I'm still kicking the idea around myself, not so much for increased lift but for durability of front end components. I don't wheel mine when it's running but I will use it for hunting on some pretty crappy roads. The big draw back with the Dana 30 is no lock outs for it in stock configuration. They can be added but it's very expensive to do. You can use the earlier Ford axles but then you're using something from the 70's, that's getting kind of old. There's lots of things to consider when doing this also. I'm getting off track here. If you want a solid axle you could consider going spring under the axle. That should keep you about four inches lower than spring over. Do like Hess13X suggested. There's a ton of reading on the subject over there or you can do more reading on Pirate 4x4.com also.

Tom A, have you got a build thread somewhere?