I want to move the front axle forward some, maybe an inch farther forward than stock (so probably about 2" forward from where it is now). The rear I'm going to leave alone. I figure 103" is where I want to be, so thats about 1.5" longer than stock. I'm still not planning on taking this thing through trails like BV Carnage or anything, although I have always wanted to run Penrose.
I used an airhammer too, it makes pretty quick work and lets you stretch the metal more than just the BFH.
Its all cool man, I do have a tendency to not come close to sticking with my original intentions. My YJ was supposed to be 103" WB on 1/2 ton axles and 36's. By the time I parted it out it was on 1 ton axles and 42's. I was planning on going up to 35's with this one, but not until next year and after I built up some stronger axles. I could keep running the 32's and let the 35's sit, but where is the fun in that?
I'm not too worried about the unit bearings. Even on full DD status the Jeep only gets driven 20miles a day, and thats only when I have to get my son from daycare. If I just go to work and back then its 6miles a day. For the most part I try to drive the Passat or Audi because they both get better gas mileage than the XJ did when it was stock. I'm also planning to have a front D44 built and installed before next year so the D30 only needs to last me the season.
To be honest I didn't like the 4.56's w/ the 32's on the street. It was just too much gear. 2500rpm in overdrive and I was only doing 68mph on the highway. With the 35's and my corrected speedo I can now do 75mph at 2300-2400 rpm, but the wheel/tire combo is so heavy I can't comfortably go that fast and the Jeep is constantly downshifting on hills. At least when I was putzing along at 68mph before I never had to down shift, so between the 2 I guess I'll stick with the overkill gearing. Besides, its awesome on the trail.