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I've thought about contacting Aqualu to see if they'd sell a pair of rear quarter panels,,, no idea if they would or how much it might cost.

GenRight still makes some (only blanks though without wheel cut-outs). Hold on to your hat (and bend over) when you see the price they want! If you can settle for steel, I know that TNT makes them still.

Just a hunch, is the lower steering column or coupling rubbing on anything (radiator hose maybe)?

Looks like you have some cutting to do. I'd cut as close to the bumper as you can and mount some OEM style brackets to the frame ends. Then add a HD rear cross member, and you should be good to go with whatever bolt-on bumper you want.

I'd try to get one that hasn't been "tested". Who knows, maybe the tester is cooking them somehow?

LOL... that's a good one!

I like to pop the port plugs and drain as much assembly fluid as possible, then fill the box with new fluid as much as possible (takes a little while to let gravity do it's thing) before mounting or attaching hoses. Once installed I jack the front wheels off the ground and cycle the steering...

It should fit with a skid made for 15 gal tank. Or you could use the old OEM 20 tank with a new skid plate.

IIRC, the rail closer to driver side controls the front output and the one closer to passenger side controls the rear..

Probably the lockouts are the weakest point (intentionally so). Chromoly shafts are a popular upgrade along with a 30 spline carrier. Not much you can do about the ring/pinion gear. At some point it probably becomes cheaper/better to get a D44 (or D60).

Sounds fishy to me. I'd measure the housing diameter before installing to make sure it's the H1 box.

Assuming you've already tried penetrating oil on the threads and hitting it with a hammer, you may have to drill/cut the head off.

Where did you find one?

Bumpers tend to bump stuff (or get stepped on). My concern would be road gravel kicked up by traffic (or my own tires) as much as scrapeing on boulders. Cutting corners because I'm in a hurry usually seems to bite me in the behind eventually. YMMV.

I'm a believer in epoxy based primer especailly for something like a bumper that can take some abuse. I'd media blast first if possible.

I like the inverted square plugs so you can just click a ratchet/breaker-bar on it (no socket required).

You can BRIEFLY ground the wire to see if it moves/pegs the gauge (indicating the sender is probably the issue... either shot or maybe too much teflon tape preventing thread ground), or if it stays at zero (indicating the gauge is shot, or the wire is broken).

Looks great. Are you going to have a roll bar/cage of some sort?

Don't recall the details but there was someone on e-bay selling rebuilt gauges that were reported to be pretty good. What is wrong with your gauges?

All 4 one or All 4 Fun? If the latter, I've been to several in the past. It's a blast, but there are quite a few people, so you need to have some patience at times. This year may be interesting since we had such a heavy snow season.