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I would NOT recommend the inexpensive universal power window kits with the flexible center section. My experience is that these lack the power to open and close these windows. You will likely need to replace the manual mechanisms too, as they rust and bind. Not cheap.

Oh, yeah. Check for a wobbly old style fan too.

I digress. Military trucks, tumbles, and heart attacks.... In the last couple of years HUGE numbers of people in the US have retired. In fact, this is the largest population EVER to retire in the US. The top causes of death among these people is a fall or myocardial infarction (heart attack)...

All of this comes from a common arena, the AAMVA. When you do battle, be sure to go to the AAMVA website to get a feel for their issues. Most are baseless. Please do not send nasty emails to them. They just need to be educated. From what I read, they don't want to take the time to categorize...

I don't have any hints for the radiator, but while you are in there check the fan clutch, fan air tubing, remove driver's side front engine cover (at injection pump) and check that bolt is tight on gear.

Excellent!

Hit those rubber boots with a spray of ATP AT205, to soften them up so they won't crack.

How much deflection up are you going to allow for on the rear tires when it pivots ?

I used to live there. MI people need to fight this tooth and nail. Get a petition going. They are using classic AAMVA tactics which are based on false narratives. They need to understand that many of these vehicles WOULD meet the EPA requirements for their respective time periods. They also...

https://www.lansingstatejournal.com/story/news/2020/02/19/bill-allow-military-vehicles-humvee-michigan-roads/4795857002/

In some cases can be fixed, or replaced as Beastmaster said. Used one from a later model would work too.

There's a windshield seal on Ebay.

Go to the Steyr forum and ask.

There have been some, but pretty scarce. Other options would be universal windshield and window gaskets, or order Steyr gaskets.

I'm going to try your technique today : )

Honestly, anything rubber or plastic will likely need to be replaced. Plan ahead. You CAN do this! The MV support network is strong on Steel Soldiers. There is a wealth a information on here. If you break down, I can pretty much guarantee SS members will come to your aid. People like Suprman...

I am doing pretty much the same type of build. I bought mine from GovPlanet. Here's what I have learned: The guys who work the MV lots know a lot about these vehicles. And they can be a big help. Might even throw in newer batteries or something if you get to know them. Ask them what they think...

I will eventually show it. Secret for now : ) Definitely NOT using 100 watt panels.

Split, not spit. I guess if you spit a while you could cool off :) Yes, 7200 watts in panels : ) Outback and Midnight Solar. Why so much? Why not? Having had solar for years, I have my logic ; )

Everyone has different needs. For year round Overlanding, get the A/C. For occasional use, use whatever. Look at the nice vents Sean added too. I have a 2nd gen. Bought for $400-500. Now the price is much higher. Honestly, get 33.lk btu at the best price you can and call it a day. If I was...