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Ronin8002's 4th Gen custom coilover conversion

Discussion in 'Offroad Projects' started by Ronin8002, December 20, 2012.

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    1. Ronin8002

      Ronin8002 Well-Known Member

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      I'm going to be doing a project over the holidays to convert from the stock OEM style struts in the front of my 2008 4x4 Explorer to Fox coilover shocks.

      The goal is to get a mild amount of lift (around 2.5") and increase the front suspension travel.

      In stock form, the 4th Gen OEM front suspension with the OEM type struts has a bit over 4" of wheel travel.

      I will be using Fox 2.0 Emulsion coilovers with 5" of travel. If my math is right, this should result in about 8.5" of wheel travel available (will probably be slightly less than that since I'll need to run limit straps)

      I am going to do everything possible to make this a bolt on installation as far as the way the shock brackets are designed. So far, I've just gotten the shocks and springs (10" 750lb spring rate eibach coils) and extended lower shock eyelets.

      [​IMG]

      I think it would be possible to run a 6.5" travel shock, but the front diff might have to be dropped down a bit with brackets in order to reduce the stress on the CV axles at full droop. So for now, I'm staying with a 5" travel shock.

      More to come.
       
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    3. Kazer

      Kazer Well-Known Member

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      Subscribed! i'd love to see this as a purely bolt on kit
       
    4. Mr Dubya

      Mr Dubya Elite Wannabe Explorer Elite Explorer

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    5. rangermidtn

      rangermidtn Active Member

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      This should be a little easier for the 4th gens than the 3rd gens. Your control arm looks a little easier to work with than ours. I am redoing mine again, due to the way the 3rd gen curves were you will put your mounts.
       
    6. renzAy34134

      renzAy34134 Active Member

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      I thought u said that you werent going to domany mods to this one? lol

      Anyway this should be pretty awesome. Did you get the new UCA yet? I think I remember reading that you go them with the truxxx lift.
       
    7. Ronin8002

      Ronin8002 Well-Known Member

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      Yeah once rangermidtn started talking about coilovers on his 3rd Gen I realized I could probably do it too. :D After doing a little offroading I saw that I definitely needed the extra flex.

      I have my BTF UCAs on a shelf in the garage...will put them on when I do the coilover install.
       
    8. Ronin8002

      Ronin8002 Well-Known Member

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      Upper brackets are basically done.

      Made them out of 1/4" plate for the flat parts and 1/4" wall rectangular tube for the "tab" portion.

      I used the rectangular tube because I needed to have 3" between the OEM strut mounting surface and the center of the mounting hole for the new shocks. All the shock tabs I saw online were too short...I needed something that would be long enough but also very strong.

      Additionally, I installed some thick weld washers to strengthen the areas where the shock holes are. This will also prevent the shock holes from getting "ovaled" out over time.

      Here are the pics...still need to smooth out some of the rough edges and position/weld the rectangular tube to the plate:

      [​IMG]

      [​IMG]

      Once these are done I'll be ready to do the lower mounts.
       
    9. rangermidtn

      rangermidtn Active Member

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      Looking good!
       
    10. rangermidtn

      rangermidtn Active Member

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      Hey Ronin, did you shocks come charged with nitrogen, or do you have to go do it?
       
    11. Ronin8002

      Ronin8002 Well-Known Member

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    12. rangermidtn

      rangermidtn Active Member

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      Thanks, you got these from poly perfomance right? I am thinking about ordering the 5" for the front and the 6.5" for the rear.
       
    13. corkey

      corkey Moderator Emeritus Moderator Emeritus

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      just so as you both know,, my Fox 2.0's are charged to 300 psi of nitrogen,,
       
    14. corkey

      corkey Moderator Emeritus Moderator Emeritus

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      and,,,,

      it would seem the race is on, to see who's rig is on the coilovers first,,

      but i think a same day photo unveil would be so sweet,,
       
    15. Ronin8002

      Ronin8002 Well-Known Member

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      Yep, went thru poly performance for everything.
       
    16. Ronin8002

      Ronin8002 Well-Known Member

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      Lol, well rangermidtn is way ahead of me. I've got some extra time for the rest of the week though, so hope to get closer to finishing.
       
    17. rangermidtn

      rangermidtn Active Member

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      Don't worry you will probably catch me this week, starting tomorrow rain everyday here.
       
    18. Brandon96

      Brandon96 Well-Known Member

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      When are you going to stop doing cool crap James? .. :thumbsup:


      How's that running board by the way? lol
       
    19. DominicanX

      DominicanX Active Member

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      Yeah man, looking good on those brackets!
       
    20. Ronin8002

      Ronin8002 Well-Known Member

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      Started the lower mounts yesterday. Hope to have them done by the end of the weekend.

      haha, thanks. that running board is still holding up...just cracked the outside edge. Sometimes when the wind is right on the highway it will rattle, but otherwise I forget its there most of the time. I am planning to build another set of sliders in the spring like what I made last year for my old truck.
       
    21. DominicanX

      DominicanX Active Member

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      Let me know when you're ready to build sliders for my truck ;-)

      Well mounts for them. i think eventually i'll go with the Trail Gear sliders.
       
    22. Ronin8002

      Ronin8002 Well-Known Member

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      Once you get the sliders come on by and we'll build some mounts :thumbsup:
       
    23. Ronin8002

      Ronin8002 Well-Known Member

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      Lower mounts done. I'll post some pics tomorrow when I test fit everything, then I'll prime and paint them.

      Should have the coilovers installed before the end of the week.
       
    24. rangermidtn

      rangermidtn Active Member

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      Can't wait to see them.
       
    25. corkey

      corkey Moderator Emeritus Moderator Emeritus

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    26. Ronin8002

      Ronin8002 Well-Known Member

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      Test fitting went pretty well today. First, a couple shots of the brackets:

      Lower bracket on the left, upper bracket on the right:

      [​IMG]

      On the lower bracket, the triangle shaped tabs are for the shock (just tack welded on in these pics) and the square tabs are what hold the whole bracket onto the lower control arm. you just take the OEM lower shock bolt and run it through the holes in the control arm and the bracket, then tighten down the nut. I didn't have an 18mm drill bit so I drilled a 3/4" hole. Tiny bit looser than I would have liked, but the head of the bolt will hold it pretty tight when it's snugged down. Just to be sure though, I will be welding a nut or washer on the inside of one of the two tabs to take up the slack and make sure the bolt holds the lower bracket on even more tightly.

      Another shot of the brackets:

      [​IMG]

      and fitting it up:

      [​IMG]

      [​IMG]

      I had to move the lower shock tabs more forward (close to the edge of the lower bracket) than the stock strut position so the bolt head would clear the CV boot when the suspension gets compressed. It's about a half inch clearance but its enough. The only downside to this is the increased angle on the shock made the shoulder on the upper shock eyelet touch the edge of the upper mount tab. I'll just grind a little bevel on the mount tab to clear it.

      Getting close now, thanks to rangermidtn and corkey for their help so far!
       
      Last edited: January 15, 2013

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