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5spdman's slow and cheap XLT build

Discussion in 'Modified 1991-1994 Explorers' started by 5spdman, March 11, 2014.

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    1. mr cribb

      mr cribb US Army Retired Elite Explorer

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      Yup. Remove the trim, unbolt and lay a new bead of windshield silicone.

      Buy the bigger tube, because the small tiny one in the package does half the window. (Just saying from personal experience).
       
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    3. 5spdman

      5spdman Elite Explorer

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      Resealed the rear glass for a cost of about $6...I'll have pictures in a write-up coming soon and attach the link here.
       
    4. 5spdman

      5spdman Elite Explorer

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      Well I went ahead and got all the parts I need for the extended RA's, or at least ordered...6" springs are on back order. Until then, I figured it was a good idea to get done what I can for the moment.

      Material for the brackets was donated from the frame of a 97 Ranger...

      [​IMG]

      First step (other than drawing and making patterns) was to get the material cleaned up...angle grinder made fast work of getting rid of rust and paint.

      [​IMG]

      Pieces were then marked and cut out with cutting wheels.....a lot of cheap cutting wheels.....

      [​IMG]

      The sections of material I was using wouldn't leave me enough to make the brackets with 3 pieces, so I had to extend the piece that will rest under the frame...

      [​IMG]

      Both edges were beveled, and then it was time to get to work... :)

      [​IMG]

      [​IMG]

      [​IMG]

      A little angle grinder action and die grinder/brush and it almost looks like it started as one piece!

      When I have time, the other side will be added to as well. Will borrow dads bench grinder and get all the parts shaped up to size and to match and then get all holes drilled. After that, it's getting the other pieces welded on and everything cleaned up. I'll wait to get the tube onto the stock RA's, but will probably go ahead and get the heim bungs welded into the tubing so it's all ready to go when the springs arrive.

      More updates to follow, so stay tuned!
       
    5. 1992explorerMi

      1992explorerMi Active Member

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      Hey man im picking my truck up another 2.5 inches at the end of the month and want to extend my RA s keep the pics coming so i can steal your ideas. Lol
       
    6. 5spdman

      5spdman Elite Explorer

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      Haha, they'll be comin!
       
    7. 5spdman

      5spdman Elite Explorer

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      Got a lot done yesterday......

      [​IMG]

      Got all the bracket pieces made and shaped the same/similar...next step is to drill them so that the holes all line up when welded together.

      And speaking of welding...

      [​IMG]

      [​IMG]

      Heims are in and ready to go...hoping to get the holes drilled and brackets finished this week sometime...still waiting on those springs....until then, I'm just using my time...
       
    8. 5spdman

      5spdman Elite Explorer

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      Well, as the rain slowly comes down (not like it is in TX), I didn't have work today....so I worked for myself...

      [​IMG]

      Brackets were drilled last night (to at least get the hiems in) and I went ahead and got them welded up...

      [​IMG]

      I couldn't help myself, so I went ahead and put everything together...so ready to have this done lol!

      [​IMG]

      I have one more plate to weld on that will provide some protection and also stiffen up the bracket. None of the mounting holes are drilled yet...

      When "mocking" up the side plates for mounting, I realized I had a flaw in my plan...I was going to run into the trans crossmember...I believe I've figured out a way to modify the crossmember and still leave it strong, but I MIGHT leave that for the weekend...or I may not...will need hardware for remounting the coil buckets once the shock towers are integrated, so a trip to the hardware store may land me at the fire department (where I can work out of the rain) and modifying the crossmember.

      I do have an EMT quiz to study for though...I'll just get that out of the way right now so I can get back to work on the truck... :D
       
    9. 5spdman

      5spdman Elite Explorer

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      Speaking of mounting them, I'm going back and forth on bolting the mounts to the frame or just welding them...any opinions?
       
    10. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      If it was me, I'd weld it and be done. drill you some holes on the mounting sides though and get some good plug welds. Only drawback I see if you ever had to replace em for any reason. Bolts would be better then. Probably just me but I get paranoid about hardware loosening itself.

      Looks like your new welder is treating you pretty good huh? Not much you can't do with one of them. I've had my little Lincoln for about 13-14 years now. There's definitely times I wish I had a 220v machine to run hardwire and gas, but for the portability, you just cant beat a little 110v with flux core. Could weld 2 soup cans end to end in the middle of a hurricane.
       
    11. 5spdman

      5spdman Elite Explorer

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      I think I've decided on bolting them, just in case, for some odd reason I'd want to remove them...

      And yeah, the welder is working awesome!! The other reason I had went with this one was that it does offer the option of hard wire and gas. Yeah, a 220V unit would be superb, but this will work just fine! :)

      Speaking of just fine, I'm super impressed with Bronco Graveyard...

      [​IMG]

      Opened the garage to let the dog in just a little while ago and found these inside the door!! Had contacted them earlier this week, as they were on back order, hoping to find out when they'd get here. Jeff contacted me and said they may get them by Friday. Well, last night I got an e-mail saying a shipping label was made, and here they sit today!!

      If we weren't going to the in-laws this weekend, I'd be working tonight and tomorrow to get this sucker done...will drill holes and finalize welding tonight and tomorrow along with modifying the trans-member all before we leave, and hope that next weekend will hold some glorious weather!

      Also, for the time being, as I seem to have material available and want to limit the amount I spent at the moment, I'm going to fab some rear shackles to even out the lift for now...may work on those tomorrow as well...
       
    12. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      I've ran the same Lincoln I have at one of my jobs with hardwire and gas was less than impressed. Was nice for spotting sheetmetal together but penetration just wasnt the same.

      You're a better man than me, no way I could walk away from those sitting in a box, LOL.
       
    13. 5spdman

      5spdman Elite Explorer

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      Well, I'm getting closer to walking to them and getting them out lol....I'll just leave these here to explain...

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]

      [​IMG]
       
    14. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      Now I'm pickin up what you're puttin down, LOL. Whats your plans on the radius arm drop brackets? Not sellin thise by chance are ya?
       
    15. 5spdman

      5spdman Elite Explorer

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      Plans are, I won't need them and they'll be up for grabs...
       
    16. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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    17. 5spdman

      5spdman Elite Explorer

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      Noted :)
       
    18. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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    19. 1992explorerMi

      1992explorerMi Active Member

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      Hey is this going to make the ride extreamly rough. With the heims you have no give at all right.
       
    20. 5spdman

      5spdman Elite Explorer

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      No give, but I'd don't want my beams moving forward or backward...the old bushings don't give all that much either...all the give is in tires and suspension...

      The hiems will just allow for better range of travel...
       
    21. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      The way to go in my book, but for those of us who just dont have the $$ for everything at once and have to do a little bit at a time. going the route that Caleb has on the whole thing is about as light on the wallet as you can make it and still get out for some wheeling. So hard to be patient sometimes though!!
       
    22. 5spdman

      5spdman Elite Explorer

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      Truer words have never been said...thinking of taking Friday off work to get it all done lol.
       
    23. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      I wont tell anyone!!
       
    24. 5spdman

      5spdman Elite Explorer

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      Gearing up for Friday...still looking for some tall jack stands to keep the front end up while doing the coils and shock towers, but got the last step to the hiem brackets done...

      This was Monday evening:

      [​IMG]

      The top left bolt looks a little goofy because it wasn't fastened...there's a second layer behind the frame that sticks out and, for starters, the bolt wasn't long enough and I managed also to drill where it comes back to the frame, leaving an offset...that will be addressed...

      And now for how I leave the brackets tonight until the weekend:

      [​IMG]

      [​IMG]

      PAINT!!! :bounce: Bring on the weekend!!
       
    25. 96EXXLTinCO

      96EXXLTinCO Elite Explorer

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      BTW, what exactly were the springs you ordered? I see a sticker for BDS, are they specifically for explorer/ranger? Thought I almost had my hands on a used 4" kit here locally but I got beat to it. Then the guy that did buy it sends me a message asking if I still wanted it. Come to find out it didn't have the axle beam drop brackets!! Just coils and radius arm drop brackets. Trying to find those beam brackets is tough, at least for me, haven't found anything so far.
       
    26. 5spdman

      5spdman Elite Explorer

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      I posted a link to the site...they were labeled as Ranger/BII 6" lift coils, but as we know, a lot of RBV parts are interchangeable...everything measures up the same but height...

      Sucks about the brackets...need some made? Lol
       

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