Ok, the gearing modification is almost done! All I need to do is put the trans back in the car. As far as I know this will be the second 3S to have this modification done to it. So here are some pics of the work:
Pics: 5 speed trans, 6 speed T-case.
A bit of grinding on the 6 speed t-case, makes for less grinding on the transmission.
A nice close fit
Not particularly useful with out before and after pics, but shows the contour that is need to fit the 6 speed t-case on the 5speed trans. Stock the webs are close to flat between the top and bottom.
A sharp eye will notice the top left and bottom center bolt holes have weld around them. Material has been added and the holes moved about 1/4 to 3/8" to properly line up with the 6 speed transfer case.
That stuff, along with a new front ring and pinion, a spacer and a slightly longer drive shaft and the you have the shortest possible gearing for a 3S. If you are wondering why all this is necessary, it's because the 5 speed and 6 speed t-case's have significantly different ratios. The rear diff ratio and t-case ratio need to work out to be the same as the front ratio. And as mentioned earlier, there is no alternate gearing available for the 5 speed. I could have swapped in a 6 speed, but they come with their own set of problems, like $$$ and they are a little weaker.
Other mods started over the winter and to be finished are a nice new Kirkey seat, 5 point harness and a couple of mufflers to be installed.
A big thanks to John for all the help!