It seems I've been collecting parts more than getting much accomplished. I recently purchased a H1 Hummer complete 6.5 TD with 4l80e with only 12,500 miles on the clock. I've been trying to source all the electric connectors to keep things 'OEM' looking and make trouble shooting easier down the road. I've shifted my intent on going with the early mechanical pump to keeping the late electronic one and all the electronic controls such as throttle,cruise and transmission. I found a B/W Morse transfer case built for a Revcon that's only 12"x21"x5" and only needs a simple 3/4" adapter to work. I also sourced the Dana 70 from the Revcon but am having a real challenge adapting the 1 ton chevy outboard CV's to a simple u joint. I may have to use the AAM 9.25" IFS chevy axle I have. I know the Dana is stronger but I'm at a stand still right now.
I've been looking for a supplier for a 8.5", 3/16 frame to give me a 2.5" body lift. Found someone that can do it in 1/4" but I don't think I need that much meat here, after all it's only 1/8" stock.
I've also found a couple of companies that sell a modified valve body and computer to turn the 4l80e into a 5 or 6 speed. You really need to change the 1st/second gears to take advantage of the extra gears but I don't think an extra $3000 for the modification would be worth it.
Thanks for the interest Bill, I'll try to document the build with pictures as I go.
Hal

...I've been looking for a supplier for a 8.5", 3/16 frame to give me a 2.5" body lift. ...

I bought an engine/trans from a 12,500 mile H1 Hummer for $3000, I paid $100 for the transfer case and $100 for the Dana 70 and stub axles. I do most all of the work myself. I guess I don't get the 'money' comment.
Hal

Would anyone have the dimensions for the CV flange to flange width of our final drives? I'd like to get the dimensions pretty close, better than I can manage from under the coach. If someone had one on a bench that would be great. I'm trying to work out the axle lengths needed on the diesel swap and which IFS to use. Any help would certainly be appreciated.
Thanks again,Hal

Is that measurement from the outside flange or from the flat area where the cv flush seats? It's probably only about a 1/4" recess but I'm trying to get as close as possible. Thank you, Hal

The dimension I gave is the overall out side distance from where the inner CV bolts to the face. The recess there is to accommodate the seal cup of the inner CV joint. Of the two dimensions one could get the one I gave is the greater of the two.

I'll post some pictures a bit later tonight.

Thank you so much Steve,that's perfect. I owe you one.
Hal