Parts arrived - machined adapter plate, coupling hub, bearing and taper-lock. I also found an aluminum flywheel on e-bay for a great price. I'll remove the starter ring gear since I don't need it.
Template for trimming the motor end plate.
Trimming the motor end plate to clear the transfer case and align with the mount plate. I must say, I thought hogging out some aluminum would be easy. But when you are dealing with 1" and 2" thick parts - its quite another story! Most trimming was done with a 3/4" carbide bur on my die grinder. At a slow speed. The aluminum tends to gum up any kind of cutting tool if the cutting speed is too fast.
Checking the motor fit.
Checking the fit with the transfer case installed.
Transfer case removed to show the profiling.
Motor and adapter plate bolted up to check fit.
Transmission bolted up perfectly. Temporarily installed the motor/transmission assembly to check motor mounts and clearances.
It fits !!! And with an extra 1-1/4" clearance to the frame. So I'll be able to use the auxiliary shaft output if I want to drive the power steering and/or A/C.
I mocked up the 4th motor mount bracket out of some styrofoam poster board. Its easy to work with and a hot glue gun firmly holds the pieces. I also incorporated a power steering mount that is similar to the factory location.
I also mocked up a torque arm. But I don't think this is strong enough. There are only 4 - 8mm cap screws holding the motor to the aluminum end cap. I'm going to have to come up with some kind of banded mount. There is no way those 4 small cap screws will handle 250 ft-lb of torque!
