If you don't want to do allot of Fab the 416 with disk brakes is probable the way to go. You can swap out the 2 huge stock calipers with a toy calipers and fit a 17" rim. Not sure if you need to mess with the pinion on the 416. You do on the 404.
There are also some people making custom billet Volvo portal boxes. And the hummer portal box is defiantly an option. Plus you have the benefit of being able to get parts for the hummerÆs boxes where you'll be looking at a whole new axel if you manage to break a mog or Volvo box. Not likely but it has been done.
And the hummer is more suited to highway speeds than the mog or Volvo boxes. Although you could easily add an electric oil pump, cooler, and some lines to the mog/ Volvo boxes.
The only issue I see with the hummer box is that its aluminum so you canÆt weld directly to it if you want to change the stock hub/brake assembly. Although I have seen several bolt on setups that are pretty slick.
If youÆre thinking about hummer/Volvo boxes of course where talking ford 9ö centers. And there are tons of gear / locker options for the ford nine. One small thing with the 9ö is the pinion bearing will have oiling issues, (cuz its upside down because of the portal)) so you would need to add an oil scoop, but its fairly simple and there are several threads on Pirate about it. I think sunray engineering also makes a more professional oiling setup too.
One nice thing about the Mogs, they have a lever actuated locker. IÆve seen lots of people add a small air ram to it, and itÆs pretty simple, so not much too break.
Some links below:
http://www.classicunimogs.com/index.htmlhttp://www.exaxt.ca/axle.asphttp://www.killeraxles.com/html/portal_axles.htmlhttp://differentialeng.com/http://www.sunrayengineering.com/main.htmlhttp://www.cs.brandeis.edu/~zippy/unimog-404.htmlhttp://www.bc4x4.com/fv/2002/hulk/http://en.wikipedia.org/wiki/Universal_Motor_Ger%C3%A4thttp://www.unimogwherehaus.com/http://www.pirate4x4.com/forum/forumdisplay.php?f=28http://www.pirate4x4.com/forum/showthread.php?t=394177&highlight=volvo+portalhttp://www.pirate4x4.com/forum/showthread.php?t=427867&highlight=volvo+portalhttp://www.pirate4x4.com/forum/showthread.php?t=414817&highlight=volvo+portalhttp://www.pirate4x4.com/forum/showthread.php?t=407619&highlight=volvo+portalhttp://www.pirate4x4.com/forum/showthread.php?t=330747&highlight=volvo+portalhttp://www.pirate4x4.com/forum/showthread.php?t=392613&highlight=volvo+portal
