Cutting the 3/16-inch steel...
Cutting the 3/16-inch steel plate with a hole saw would've been an option, but such a method requires a lot of patience and sweat. Plasma cutting is much easier.
Plan A was to sell the rolling chassis minus the transmission and transfer case to someone who would finish the Phoenix and put it back on the trail. Plan B was to strip the chassis of all the good hard parts and take the frame and cab to the scrap yard. I sent a couple of messages along the grapevine to see if there were any takers. Ultimately, the grapevine proved its worth, and a 'wheeler named Jeff Simpson stepped forward to save the Phoenix from the scrap yard.
What pearls of wisdom have been gleaned from this experience? It's good to dream big, but it's essential to mix those dreams with stark reality. There are only so many hours in a day to work on a project. Get to know the difference between a stretch and what's truly beyond your reach. In my case, one major vehicle project was a stretch, but two major projects were simply beyond reach. It's also best to conquer denial sooner rather than later.
After the Ranger project is finished (this is Project TrailRunner in Off-Road Magazine), I'll look around for another trail rig to build. In the mean time, I'll drive the 4Runner UNlimited on mild trails and sit shotgun in other peoples' rigs on the tougher routes.
Read on for the details about the foundations of the engine cage, the new owner, and the significance of paint.
 The frame needed to be level...  The frame needed to be level before an engine cage was created. A pair of pipe stands offered the perfect combination of strength and adjustability. I temporarily welded a length of steel tubing to the front of the frame, and the ends of this tube were set onto the pipe stands. A SmartTool digital level made it easy to tell when the frame was properly positioned. |  I decided to ditch the stock...  I decided to ditch the stock core support mounts at the front of the frame. Tubing, plate, and urethane bushings took the place of the old mounts. |  The -inch holes I needed in...  The -inch holes I needed in the center were created with a bit and a drill press. |
 Since my plan was to ditch...  Since my plan was to ditch the leaf springs in favor of links and coilover shocks, I planned to delete the front spring hangers and the core support mounts above them. The new core support mount retained the stock core support placement, as no body lift was used. Just behind the crossbar, there's a temporary brace welded in to position as the core support during the new mount's fabrication. This temporary brace was cut out after the new mount was built. |  The engine cage was designed...  The engine cage was designed to bolt to the frame. Through-bolts would be used wherever possible, but one of my chosen locations was blocked by a motor mount on the other side. I needed to bolt into a threaded, blind hole. To make this happen, I welded a nut to the back side of one of the 3/16 thick washers made by DMZ. Next, this washer was welded to the frame. Done. |  The old shock hoops had to...  The old shock hoops had to go. A Sawzall and grinder made them disappear. |