What would be a safe tire size in 16" that wouldn't require me to re-gear?

 

I would say 31" anything after that sucks getting up to speed.

 

I drove our shop rig today. has 31's on it with stock gears. its sluggish and sucked gas today.

 

I would say you could run 32's no problem but it also depends on what gears you're rolling now. Out here in the midwest most of us got 3.55 stock and it sucks, but I'm rolling 265 75 16 on stock drivetrain and i can still get around 15 in town when I don't straight mash the skinny pedal. I think they equal a 32.2 or some crap like that. Anyway, I am still able to get up to speed alright without worry. If I jusmp to 34 this summer I will prolly end up going to a 4.10 or so. I don't know if this will help you, but I hope so. Gears are not cheap. But on the same token I am putting my drivetrain through a little more stress than I would like. All in all I do like it though, Especially in winter when I can avoid digging myself a hole with relative ease, while my buddy with 4.10 and 33 12.50 just burries himself all day long. Works well on sand too.