I decided to pull out the 4.56 gears and swap in a set of 4.10 gears. Also decided to pull the fuel cell out of the trunk and build a custom 20 gallon tank to fit in the kick up area between the wheel tubs. Both projects are underway but neither one is proving to be easy! I was able to pull the Dana 60 apart but putting it back together requires some tools I don't have so I'm waiting for those. Doctor Diff set me up with the new gears as well as an install kit and a bunch of advice. I've also been following the FSM as well as this document from the Strange Engr website: https://www.strangeengineering.net/dana-60-gear-installation/

The FSM is useful but not spot on since the Strange S60 has side adjusters and some other little details that are different. Besides, the FSM approach is super complicated with expensive checking tools for pinion depth and such. Everyone I've talked says to just bolt it together, check the pattern and go from there.

The fuel cell project has been interesting. I think I've figured out how to solve the various issues I had with the cheap off the shelf fuel cell. I did a bunch of research into fuel cells and came to the conclusion that to run an EFI system on the street I needed a custom tank. I wasn't confident enough in my design knowledge to draw up a tank and have it built so I decided to work with a local chassis shop to customize an existing tank. We're adding a sump, replacing all of the mounts and brackets, redesigning the vent system and the filler tube. I'll snap some pictures once I start getting parts in hand.

Thanks. It is a fun car to drive. It goes straight, handles pretty well, stops really well and goes hard when you get on it. It is noisy inside due to all of the bare tin but I think I could solve that by having an upholstery shop install some carpet. I do have a few things I'd like to improve on it such as putting a larger fuel cell in it and replacing the floor in the trunk. I'll also need to change the gears at some point since the 4.56 gears are just too steep for this engine. I think 4.10 gears would be better but I might need to drop down to the 3.90 range. I need to get more miles on the car before I'll know for sure. Here is another picture I snapped. Working on my car photography skills......

Dana 60 guys might be interested in the cover that I picked up. I had an LPW cast cover on there which I decided that I didn't like anymore so I pulled it off. I wanted a simple steel cover but I didn't want a cheap Pep Boys chrome cover. Turns out that Spicer sells a heavy duty bare steel cover for $38. This cover is made from 1/8 inch steel so it is much stronger than the original factory covers or the chinese tin covers. I was going to clear coat it but then I decided to get it nickel plated with a batch of parts. Turned out really nice.

Count me in for one AR engineering Dana 60 cover please!

I want to see the fuel cell, Im very partial to A bodys and ANdy you make some very nice parts/pieces !

This is such a nice "modern" car. But i like "modern" with the "old" engine. Not a new gen hemi..LOL

I was having trouble installing the pinion back into the housing by myself so I made a tool that presses the pinion in place from the rear. With the pinion held in place I was able to tap the front bearing on and then tighten the nut on the yoke. I talked to a buddy who does rearends on a regular basis and he said he just has his helper hold the pinion so he can get the front bearing tapped into place. Strange Engr recommends polishing the pinion shaft so the front bearing slides on but I didn't have the tools to do that.

Rigged up an old fashioned torque wrench to double check the pinion pre-load. I have a small inch-lb torque wrench but the numbers are so small it is easy to fool yourself. A weight on a lever is hard to fool.