Wow...been a long time since I've even looked at this thread. However, I made a bit more progress so I figured a post was needed. I don't know if I had mentioned this, but when I got Copper driveable 36,000 miles ago I had not built a front driveshaft. Funny thing, with the rear locker and the suspension/tires/horsepower- I haven't needed one...until Snowpocalypse this winter. I priced a yoke and shaft, but got to thinking- I've got a bunch of parts I've collected, maybe there's something usable. I found a front CV shaft that was almost new, and a rear CV yoke off a 205 case. A little machining on the yoke, 1 1/2" removed from the shaft, and I've got 4WD! With the front locker this thing now officially has "Beast Mode". We've gotten over 4 feet of snow over the past couple months, plus some rain. It's now 18" of heavy, dense muck in my yard. Copper blew through it- 4 roosts of ice and engine revving. My wife came home, saw the tracks through the front yard, shook her head and commented "Looks like you finally got your 4WD working". Yes, I did!
A little tech tip on making a 205 yoke work on a Rubicon 241J transfer case. You have to machine out the splines on the back of the yoke so it will fully seat. None of the local machine shops wanted to touch it, so i got creative. A hole saw, drill press, and some Dremel clean up saved me $125 for a new yoke.