I'm Josh Cassell and here is my picture: mug shot (http://www.explorerforum.com/forums/showthread.php?s=&threadid=40920)

My Explorer is an XL 4door 4wd, but here are somethings i have added:

Interior:
-JVC CD player
-replace all 4 5x7's
-Changed the seats out with 2000 model seats
-first aid kit
-"custom" rear cargo storage space
-added 2 front power supplies and a CB (http://www.explorerforum.com/forums/attachment.php?s=&postid=441843)
-rear power supply and fire extinquisher (http://www.explorerforum.com/data/showphoto.php?photo=1170)
-Garmin etrexGPS mount (http://www.explorerforum.com/forums/showthread.php?s=&postid=442632)

Exterior:
-Rear tire carrier (http://www.explorerforum.com/forums/showthread.php?s=&threadid=56448) with Hi Lift mount
-Steel Horse Roof rack
-2 Hella 500 lights on front of rack
-2 Hella 530 lights on brush guard
-manik brush guard
-manik tail light guards
-2 Blazer lights on the back of rack
-Home made nerf bars
-fender flares (forgot what brand)
-front tow hooks (http://www.explorerforum.com/data/showphoto.php?photo=172)
-additional skid plates (http://www.explorerforum.com/forums/showthread.php?s=&threadid=43570)
-Reese roof mount bike rack

Suspension:
-Front--2" TT
-Rear--Monroe Air shocks, ad-a-leaf, shackles
-removed rear sway bar

My motor, which is the 4.0 OHV is stock. I don't know a thing about motors so i don't work on them. It has been a great motor, 123,000 miles on it now and does not burn any oil. The truck came to me as an automatic but when the second tranny kicked the bucket i changed it over to a manual 5-speed. Took a lot of time and about $2000 but it was worth it. Here is the thread and write up on my conversion: auto-manual swap (http://www.explorerforum.com/forums/showthread.php?s=&threadid=36026). I have changed the exhaust for a Flowmaster series too. Just about every thing no the truck as been replaced, literally. I call it my "lifetime warrenty truck!" The gears came as 3:73 open, so for the rear i added a Power trax no slip rear locker (http://www.powertrax.com/noslip.htm) and i love it! Since the 97's came out with the "no 2wd" option, with a little help from KMak, another member, we figured out how to disable this option with an inline switch, which now gives me 2wd. With the switch off i can still use the tcase and actually put it in low range, and be in 2wd low. It is great, i do use this a lot when i'll pulling up really steep hill here in WV. Here is my thread and write up on it: from AUTO 4wd to 2wd (http://www.explorerforum.com/forums/showthread.php?s=&threadid=41956)

My tires and wheels in the pictures below are ARE Bajas with 31" BFG AT's. I also have the cheapo grey wheels that came on it stock. I added 31" BFG MT's to them, i run them if i'm going out for a big trip or i know i'll be using my truck for off road work during a weekend, but both tires are awesome for off road and on road.

In the Process:
Dana 30 off of a 95 XJ with 4.56 gears, Powertrax Lockrite (http://www.powertrax.com/locker.htm) in it. Work is being done by Cory at CRL Customs (http://www.crlcustoms.com). I've got all 5 35's. They are Mastercrafts (http://www.mastercrafttires.com/ltsuv.asp?id=183). Here is the link (http://www.explorerforum.com/forums/showthread.php?s=&threadid=67617) to the thread for the work.

I absolutly love my truck and would not get rid of it for the world.

Here is my photo gallery: Elite Photo Gallery (http://www.explorerforum.com/data/showgallery.php?thumb=1&stype=2&si=jot017&perpage=12&sort=1&cat=500&user=2287)
A couple more sites with misc. pictures:
webshots (http://community.webshots.com/user/jot017) more pictures (http://www.jot017.20megsfree.com)

Happy trails!!

http://www.explorerforum.com/forums/attachment.php?s=&postid=432437

This is courtesy of Spas:
http://www.explorerforum.com/data/503/6507jot_mini.jpg link (http://www.explorerforum.com/forums/showthread.php?s=&threadid=67617)

Here is the build up of my Explorer for a SFA.

The axle I used is a Dana 30 off of a Jeep.

http://www.explorerforum.com/data/2/2287im000813.jpg

I bought the axle in December, so I had plenty of time work on it. I had it regeared to 4.56's. I also installed a Powertrax Lock-Rite locker (http://www.powertrax.com/locker.htm). I've already got a Powertrax No-Slip locker (http://www.powertrax.com/noslip.htm) in the 8.8.

http://www.explorerforum.com/data/503/2287im000818-1.jpg

I put these diff guards on the front and rear too.

http://www.explorerforum.com/data/2/2287im000814.jpg

Cory uses some pretty tough stuff. All of the links on the front axle use Hiem joints for the connections.

http://crlcustoms.com/images/JoshsEx/links2.jpg

The links are all customs made by Cory. All of his tubing used on the axle is 1 1/2" OD, 1/8" wall (I think).

http://crlcustoms.com/images/JoshsEx/upper2.jpg

http://crlcustoms.com/images/JoshsEx/drag1.jpg

The coil buckets we used came from a race car magazine. They are adjustable for ride height.

http://crlcustoms.com/images/JoshsEx/buck3.jpg

http://crlcustoms.com/images/JoshsEx/buck1.jpg

After 3 months of having the truck, he finally gets to test his work.

http://crlcustoms.com/images/JoshsEx/flex1.jpg

http://crlcustoms.com/images/JoshsEx/flex3.jpg

http://crlcustoms.com/images/JoshsEx/flex4.jpg

While Cory had the truck, I also had him build a proto type bumper that he designed, hoping people would like it so he could start to sell these too.

http://crlcustoms.com/images/JoshsEx/bump1.jpg

The truck turned out well. It is HUGE! I love it. When I got it back I got up the next morning and started to work on it. I had to replace all the brake lines up front, removed the ABS unit from under the hood, and bought a new PS caliper for the front.

I finally got everything put back together and painted. Here are pics of the bumper after i added two pieces of 3/8" diamond plate.

http://www.explorerforum.com/forums/attachment.php?s=&postid=638582

http://www.explorerforum.com/forums/attachment.php?s=&postid=638597

After I got it all done, it was my turn to try it out a little bit. I didn't want to flex it to hard because i don't have my limiting straps on yet.

http://www.explorerforum.com/data/2/2287dsc00023-1.jpg

http://www.explorerforum.com/data/2/2287dsc00022-1.jpg

http://www.explorerforum.com/data/2/2287dsc00021.jpg

Here is the link to the whole build up process: SAS build up (http://www.explorerforum.com/forums/showthread.php?s=&threadid=67617)


My tire choice was 35" Mastercraft Courser MT's. (http://www.mastercrafttires.com/ltsuv.asp?id=183)

Please let me know what you think, good or bad! I'll answer an question that I can. If you want some pricing on the work, email Cory at CoryL@crlcustoms.com


















Congrats on TOTW Josh and thanks for your service to our country! To anyone who may not know, Josh is stationed in Kuwait right now with his National Guard unit.:us:

Congradulations Josh! Nice truck!
THANK YOU for serving our country!!! Best to you!

Congrats!!!

way to go!!!! unfortunately it will be a while till you see this. Tell him congrats travis!

Congrats, and Thank you :chug:

Congrats and come home safe.

congrats

One of these days maybe I'll to a auto to manual swap so I can be as cool as you. Aweome truck!

Congrats and thank you for serving our country! :chug:

To those who don't know, Josh has indeed finished his SAS w/CRL customs.... maybe someone has a newer photo of his rig to post in this thread?

Congrats and we cant wait to have you back on the boards.

Very nice ride.

Congrats!:D

Awesome!! I know Josh is going to be pumped up when he sees this. He's currently in Kuwait training to go to Iraq. He should be leaving for Iraq shortly. He's out to the range and should be back in a few days. I'll make sure to email him and let him know!

Yes Josh has completed a SAS (http://www.explorerforum.com/forums/showthread.php?s=&threadid=77403) along with custom front bumper with a winch. Here's an updated picture.

wow i'm jealous,

thats a sweet looking SAS Ride!!

awesome truck mand but how come no update on the solid axle swap. sick anyway though

Congrats Josh.......cool rig :D

Stay safe over there, ok? :)

:D Congrats Josh. Hurry up and get back so you can enjoy your TOTW :)

i really like the color of your truck, could use a little brown though!

congrets!

Kelli

I updated this thread with his SAS info.

Congrats! Very Nice Truck. Thanks Josh. - U.S.A.

Congrats Josh!

Take care in Iraq!

Way to go, Josh- Welcome to the club!!!! I still remember you coming up to Paragon and running your X through all the obstacles when it was practically bone stock, and the hilarious stories you and your pal Jamie had to tell us in the restaurant afterwards ;)

Thanks for doing what you doing what you do- I'm sure if Doug knew, he'd tell me to tell you the same thing and to say Congrats on TOTW too! :thumbsup:

That is one hell of a truck Josh! Thanks for fighting for us and come back safe!

Wow what an honor. Thanks for thinking of me while i'm over here in the arm pit of the world, haha!

A couple of updates on my truck, before i left country i added some steel to the frame for the steering box since i had problems with that. I also bought some Yukon axle shafts. Upgraded with the 297 ujoint. I think that's the one anyways. I've been pleased with my truck and i hope to get a few things done with it when i get back home.

I'm glad you were able to check in to see your truck as TOTW :D The SAS turned out great. I'm looking forward to seeing it in person some day.

Take care!

Originally posted by Rick
I'm looking forward to seeing it in person some day.

Maybe we'll head out to Truckhaven or Moab one of these days!!

I plan on buying a powerstroke and a trailer when i get back. I'm wanting to make it to Thaven really bad. Isn't that normally in January?

Yes, it's normally the 3rd weekend in January, but I think we're pushing it to the last weekend in January to accomodate Diffwhackdaddy's schedule.

nice job on the explorer....all i did when i saw the pics was shack my head an say thats just insaine....:chug:...i bow down, it looks awesome sitting up so high and the paint just is kick a**....sorry i'll stop drowling...

im proud of you man! on the truck and the service! be safe. get home soon!
gabe

I would've gone with a stronger axle in the front if I were you, but it's still a nice X, good job.

im proud of you man! on the truck and the service! be safe. get home soon!
gabe


Thanks Gabe! And you're welcome.

CLB, thanks for the compliments and you aren't the first one to tell me that.

hi i´m new on this page. how can i put my truck pic on tis page.
I´m from mexico and here is not comon see a explorer 4x4

Welcome to the site Antonio. To post a picture you can become an Elite Explorer and you can upload pictures directly to here or you can have another site host a picture, right click on the image, go to properties, copy the url of the picture and then in the reply part of a post you use the img button to help you post the picture.

This probably wouldn't be the best place to put a picture of your truck, but you could start your own thread to show us your truck.

lol Very nice rig

What's the LOL for? :p

Thanks though!

This probably wouldn't be the best place to put a picture of your truck, but you could start your own thread to show us your truck.
Sorry forgot to quote this... i just got a kick out of it anyway very nice truck i love you bumper i'm looking to get one sorta like that for my ranger

I was just being polite! :D

nice truck it looks just like mine but mine is stock i am looking into a sas and nice bumper too. :monkey:

Thank you. I guess your's is the same color? I love this color, i think it looks good with the black.

I am speechless... the truck is absolutely gorgeous... the way the suspension moved when you had the fork lift uder the tires was wicked.... Way to go man keep up the good work and post some pics of you offroading... Id like to see the truck action...

yes same color just found an xj for an axle i'm very excited :monkey:

I am speechless... the truck is absolutely gorgeous... the way the suspension moved when you had the fork lift uder the tires was wicked.... Way to go man keep up the good work and post some pics of you offroading... Id like to see the truck action...

Thanks for the compliments. Sorry i didn't respond back, for some reason i don't remember getting an email about you replying here. I do need to post some more pics on here, i'll do that in a few weeks, when i'm finally home.

That's cool Monkeybone, good luck!!

how do the coil buckets work for ya, id have never thought of that

I wouldn't recommend them. They work like they should, but they are extremely noisy where the coils rub against them constantly. Just ask anyone that has wheeled with me. I'm going to make some coil buckets this spring to replace these.

very rad nice SAS. i think im gonna stay IFS for a little longer. looks great. nice bumper too.

Thank ya Alan!!

Welcome to the boards, if you stay here to long you won't stay with IFS lol :p

haha im staying ifs for a little while cause i just got it lifted 4 inches and the trailmaster kit was a horrible amount of money. but i know your right. i have a pair of 8.8's in the garage and if i hadnt just gotten it lifted and dropped to 4.56's i would have used one of them or something like that with a soa and everything. also... im building my own tube crawler and i was wondering if you would tell me where you got those spring buckets or if i would be better off making my own they dont look too complex. ill try to get pictures up on here once im done with everything on the explorer and the explorer cab tube crawler with the turbo'd 460
:exp: thanks and very gnarly truck man great articulation,
Alan
98 with a 302, ram air, chips, programmer, big block duals, add a leafs, 33x12.50 bf muds on outlaw II - 32x11.50 wrangler mtr on tech 1 crawlers, trailmaster 4" no blocks, TT, 4.56's, detroits, basket with spare and hi lift, soon completed custom front bumper with compressor, 2 100 watt lights on my safari guard, 2 100 watts on roof facing forward, 2 100 watt reverse lights, custom skids almost everywhere under it, sliders, dual 1000 CCA batteries, just got a 3 inch body lift but isnt on yet, 300 watt system, 12 disc changer

The buckets came from some racing magazine, but i wouldn't buy them again. They make a ton of noise since the coil spring rubs on them. I'd just make your own or buy some from another truck.

thanks man i think ill end up making them and if i screw up somehow ill buy some old ones. thanks for the quick reply and input. 10 mpg isnt too bad for your nice f250. my 90 lariat XLT 250 gets less than that without anything. damn greatness of the 502. thanks again man. Alan

Josh your X is awesome. I hope you can make it to the Tellico summer run. I will be SAS by then. Had tons of fun on the last Tellico run. Once again very nice clean ride man. Love the rear bumper.

Thank ya! May have to make a summer run down there to try some tougher trails.

IMO one of the best lookin x's ive seen on here...real clean work, looks great, congrats man...get some towel heads for me :fire:

Hey Josh, Pretty cool Exploder, Just got back from Iraq myself and am looking forward to getting back to work on my 92 Sport. Hope all went well for you over there!

Thanks man. And thanks for the compliments Exploder..sorry i didn't respond.

Things went well in Iraq, and it's sooooo nice to be home again!

nice rig man and i wish you the best of luck on the return home i got some friends over there and if i had a choice id take their spot.

WOWOW! very nice... I see those M/T's, how much did they cost?

Thanks for the compliments fellas. I think i gave 133 per tire when i bought those a few years back.

Well sorted - looks very usable when the going nots so tough.

Safe return

sweet rig man, sweet rig

Thank you very much!

nice truck man I too am from Hurricane,WV and have been through the ringer on my explorer but after long avail it's alive email me and we'll sling some mud.
maybe we can discuss some of the mods on the explorers ctramk@hotmail.com

one of the best looking explorer ive ever seen

I appriciate that, thank you very much!