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

DAMN!!! I'm so jealous Josh...

;) Thanks!

Nice... Another fine example of CRL Fabrications work :D:thumbsup:

looking quite awesome!

friggin awesome!!!:chug:

there seems to have been a rash of new SAS's here in the last 6 months. great to see it. :)

Thanks guys!!

Cory's fab work is awesome!

I think you're right James, it seems each one is starting to get a bit bigger and better!

Hey Josh, do you have any pics of your radius arm brackets?
Thanks!

I don't have radius arms. It's got control arms. If you go to Cory's site and go to the gallery and then my link, you'll see them about half way down the page.

just wondering if in this pic the trac bar is ripping off th frame or is it an illution

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

I'm sorry i never answered your question. It is an illuition, but i did manage to rip it off and had to have it welded to the frame.

I've had the truck out several times now and just wanted to update. I've tore several things up, none of which was any thing that had to do with Cory's work, all my fault.

So far, i've had to replace the front shocks, new perches on the rear axle, fix a couple of welds i broke, make a new trac bar mount on the axle, move the lower rear shocks mounts out about 4" on each side, put the stock shackles back on and buy a new tire!

All in all i'm extremly pleased with the truck. I wish i had some money for some stiffer coil springs, these are a little to soft for my taste, but work so awesome on the trail, it rides so good off road, i don't know if i should replace them.

At full flex, here is the amount of clearance i have left. I've done no trimming since i put the 35's on.

http://www.explorerforum.com/data/2/2287im001145-2.jpg

Just thought i'd add that i've got a winch now. Some of you saw my build up thread, but here is the link: winch (http://www.explorerforum.com/forums/showthread.php?s=&threadid=86565)

http://www.explorerforum.com/forums/attachment.php?s=&postid=745425

hey josh my name is zach by the way.. that has got to be one of the nicer explorers ive seen. I just went yesterday and bought 2" add-a-leafs for the back and B rated torsion bars for the front. I had F's i think but i got 2 more inches out of it. So my 33's should clear without rubbing. Im real happy about it but keep me posted on any new mods you do to your ex. Ill have some new things for you at the end of this weekend.

Hey Zach, thanks for the compliments. Welcome to the site by the way.

The only thing i've added since the last post was a sway bar on the front. I was able to use my stock sway bar with the stock D30 end links. Defiantly made it nicer to drive on the road.

SWEET!!!!

If you don't mind my asking how much did it cost ya?

The swap cost me about 4500 with everything. Worth it to me!

wow... i cant even tell you how good that looks. I definetly have the itch for it now. i had considered it but now it is a sure thing. i think i going to start right now.

Josh you wanna build one for me??????:D

Originally posted by pbo2274
Josh you wanna build one for me??????:D

Josh didn't build it, CoryL did.

Alright then Cory U want to build another...?

if only i could have that explorer... very nice josh

if you dont mind, about how much did that cost you?

Thank you very much sir.

I've got probably between 4500-5000 in everything needed from tires to gears to parts and then the labor charged by Cory.

Dang Josh wish I could get out that cheap. I love your X. And that thing can perform well. Look foward to riding again with you.

Dang Josh wish I could get out that cheap. I love your X. And that thing can perform well. Look foward to riding again with you.


it can be done for cheaper then that too. you just have to shop around alot. im abotu 90% complete finding parts and im only at 1800. so it can be done. but im getting my welding done for free.

Yea. My whole SAS with a Dana 60 and Dana 44 front is cost me around 7k with wheels and tires. That is including: axles, chromolly shafts front and rear, longfield joints, leafs for the front, 4 shackes, shock f&r, steering, rear disc brakes, perches, clear gearz diff. cover, drive shafts f&r, hi-steer, spool in rear, labor and other stuff but thats most of it.

yea my project total is around 3000. i got a deal on some brand new 36" tsl's from a friend so i only payed 500 for them. thats like the only reason im going to be under the 3000 mark

Yea its exspensive but worth it. I just really like how clean Josh's is. For people who haven't seen it, it is remarkable. I really love and hope I can make mine look as clean when finished.

Josh, What coils are those? I just )And I mean just as in like 4 hours ago.) got my sas done and its on super lift 5.5 coils. They are stiffer than I want. perhaps we can work some kind of trade? they now have something around 120 miles on them because I drove the tuck home.

Josh, What coils are those? I just )And I mean just as in like 4 hours ago.) got my sas done and its on super lift 5.5 coils. They are stiffer than I want. perhaps we can work some kind of trade? they now have something around 120 miles on them because I drove the tuck home.

where are the pics?

There are m ore in my thread in the solid axle registry

And many more to follow

The coils are for a cherokee. They are soft, really soft which makes it nice wheelin on rocks. They've been cut to make it fit right for the lift, so i don't know if you could even use them. All he did was just come down a coil or two and cut it, so the top of the coil is just as wide as the whole thing, know what i mean?

You wouldn't happen to know what racing magazine he got those coil buckets out of do you?

Also how is the d30 holding up to 35s?

No I don't have a clue what magazine it was. But dude trust me you don't want them. I'm working on an idea to make my own anyways, so i can get rid of these!

D30 is holding up really well. I don't get on it really hard, just because i have never wheeled like that. I did bust one u joint a couple years ago, but i've been to tellico twice and to a park in KY and i've never had a problem with the toughnes. I've broke about everything else though, lol.

Perry's fab and fiber uses a similar bucket in their race Explorers. Try giving them a ring to see if they sell them. http://www.perrysfabnfiber.com/

whats wrong with F-250 buckets from a D44 equipped truck?

There are m ore in my thread in the solid axle registry

And many more to follow


you need to rethink your steering

whats wrong with F-250 buckets from a D44 equipped truck?

was this meant for me? If so then nothing, at the time Cory had these it looked like a good idea until the paint rubbed off, lol.

I'll end up with the buckets you mentioned or make my own.

you need to rethink your steering
Whats wrong with my steering? I am open to ideas but dont see any problems. Truck drives better than stock.

Whats wrong with my steering? I am open to ideas but dont see any problems. Truck drives better than stock.

the y style steering is going to cause problems when the suspension cycles. you should switch to a deicated tie rod with a shorter draglink that hooks in to the tierod instead of the tierod into draglink or move to a high steer/ cross over steering setup.

whats wrong with F-250 buckets from a D44 equipped truck?


They aren't adjustable for ride height.

Ahhhhhh you can cut off the bottom and adjust their height on the frame before you weld, gusset them from behind.

you just cant go high enough maybe :)

And then it's permanent... Better hope the springs don't settle and if they do, better hope they settle evenly. Adjustable coil buckets are the next best thing to coil overs.

actualy i have no problems when the suspension cycles. none at all. I would change it but why change what works great?