Wanderer's Caged FW SAS

EDIT for spec's
current sofar 1-11-07
exocage done by www.bbpfab.com -Pottsy is an awsome dude..and a great friend..

SAS (solid axle swap)
hd Low pinion D44 (8lug 1 ton)converted to coils and radius arms.
sterling 10.25 moved spring pearches...(prolly gonna movem outboard later)

current setup
4.0L V6-exausted..worn out..
A4LD-still surviving..dunno why..double tranny coolers help.
Stubler..5 3/4in double reduction t-case custom made by www.4-x-fab.com serial # XFAB-01
1354 stock electric shift transfer case
TTB d35 with prototyped application from www.aussielocker.com (those guys worked with me to find an off the shelf unit that would fit the ford TTB35's..currently now offered..and my install linked from their main site)
8.8 with aluminum IFS cover and whooped/worn out L/S
35x12.50x15 TSL swampers..
VIVAIR OBA compressor from Chubby at www.4wheelparts.com PARMA OHIO store.
OBA storage via scuba tank
superlift super-runner steering
rancho 5000 shocks.
6in skyjacker 2 lift. front
added leafs and 1.5in LIFT shackles from WARRIOR (also Chubby at 4wp) re-drilled to stock length..
rocklights that get busted off all the time.
interior lights for wheelin with the kid.
and my pride of the truck..
DANCIN HULA GIRL..shakin her money maker down every trail!!

hacked all the lift and axles out..
rebuilt the HD44 bearings/ball and U-joints (upgrade to spicer 760's Via Cowboy from COWBOY'S MUDRUN at Heath,OH NAPA store)
moved sterling's pearche in about 2in each side..and 3/4in thick Ubolts from S&S spring Mt.Perry,OH..(those guys are great!)
custom crossmember.
custom axlemounts
6in EB coils (softer spring for better ride/flex)
Craiger 15x7 8 on 6.5 rims to keep my 15's
custom beadlocks from www.DIY4X.com

building radius arms currently..ran out of mig wire..




older posts...will try to get most of the info transfered to here...main thread here..

http://www.offroadohio.com/forums/showthread.php?t=1110
I got a bug in my butt and decided to prep the rear axle for the explorer...(after busting the 3rd driveshaft..)

so I spent 2hrs chopin off the old shock mounts and spring perches...and rewelding the perches for the explorer spring width..now to get the porta-ban from work to start removing the extra webing from the bottom of the sterling..

busted shaft.


todays work..



I got more done today..brought the porta ban home from work and trimmed the fat off the axles...also got all the old brackets off the 44..


now its time for some BJ's (ball-joints :wiggle to ) and universal joints..then onto brackets welded on the front..then arms...

its commin...

what it looked like before..(well..actually its one of the other sterlings I have..but same thing)



after trimmin the fat..



44
before



after



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WHOOT!!...Cowboy is givin me the hookup...OEM balljoints AND spicer upgrage 760 joints...AND gettin HIS price from the local spring shop for U-bolts (they want $50 at the parts stores for 4 freakin u-bolts!!)...

friday it should be ready....(well had to get the u-joints shipped in...so I'll gather it all the same day)...

time to go home and pull some axles!!!

well...Cowboy and another feller from Cowboy's mud-run got me some KICK AZZ U-bolts..these suckers are 3/4in THICK...and perfect..just had to knock some rust out of the spring bracket plate..and they slid in like greased butter...

EDIT..better pic..


looks goofy with stocker tires...


now..to get the sploder flipped around..the front pulled..and THIS pile of parts assembled into a dana 44..look close..you'll see OEM balljoints..and spicer 760's for the axleshafts..knuckles..spindals..rotors..rad arm brackets for both the frame AND the axle..a can of JAZZ diet pepsi...1/2 a roll of plastic..some other tabs..garage fan made from a oven vent..and a bunch of junk....(and I'll get my dam workbench back..those have been sittin there for a MONTH!!...)



and yea yea...I know theres overspray..

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welp..more work done...





which got me this..

welp...spent a few hours searchin stuff on the net...but I did get the U-joints changed out...and found out something suprizing..

the stock joints needle bearings are 0.75 on the micrometer...
the upgrade 760X needle bearings are 0.90!!!...thats at best guess 25% thicker!!..and they look BEEFY....so much so it got my attention...

and I did take pix...but after getting them assembled and tack welded in..I discovered the pix didnt come out...oh well...
__________________
welp..got alot done today...

lemme see...got the locker installed in the d30....ur..wait...that wasnt my truck..:fro

ate pizza..and ordered the rims for the truck..the guy at summit racing went above and beyond...the us wheels I wanted had a 2/4week to 6 MONTH backorder..(minimum of 250 units before production from the company!!)...but he did point me to a set of white craigers that were about $8 less per wheel...which made it JUST as expensive to order 5 of those vs 4 of the others...should be here before xmas!!..Yippie!!!...gotta get the tires swapped so she can roll when the front is installed...

also ordered some sleved bushings and got some extra heim ends..(heck..theyer realtively cheap..and I can use them for SOMETHING...

now its off to the steering and such..probably get the axle assembled this week so I can mock and start measuring for arms...

and hopefully Donnie finds me a slip yoke male end for the driveshaft..then its cut and made...

coming along nicely..
rims
http://store.summitracing.com/partd...923105+4294793325+4294906428+115&autoview=sku


and some trick beadlocks...workin on something special...
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well...lighter work day today....ball joints replaced..knuckles back on...shafts in..spindals on...

today...cleaned and re-packed the bearings...installed rotors,hubs and brake calipers...no pix..
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well...big day around here...

got the wheels on the axle..and the engine crossmember hacked out of the way..



got the axle mocked into place..


(dont mind the weird arm..its part of the super-runner steering..and I havent taken the pitman arm off yet..so its just kinda hanging there..)


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WOW..what a day....went to the shop to make my tranny crossmember...spent 2hrs building it...and building it WRONG...

started with this...



had to....

chop 2in off driver side by the hoop...
chop 1 1/2 out of height of the hoop...
chop 2in out of between the hoop and the tranny mount...
chop 3in (built it long) off the other side to fit the mount on the pass side..
RE-WELD the 3in BACK IN..and chop 1in off the side..(I was thrilled..lemme tell ya)

drill the front mounts on the arms furter in..
and I developed a new Hydraulic drill..put the 1/2in drill in the cup of the floor jack to drill through 1/2in thick steel without wearin yer dam arms out..(arms are wore out anyway..)




but its in..clears everything..looks bad azz..took off for the shop at 10..got home at 1..just came in..been workin on it ALL DAY..but its done!!

I think Im gonna take tommorow off..


watch..my bushings will come in early..and I'll be back out after work tommorow...

Looks good, got some different ideas there which is nice to see.
What do you have planned for the engine x-member? I need some ideas to ditch mine and build something new...that monstrosity gets in the way of everything

got home from work today...and I had a BUNCH of stuff waiting for me..and another package to be picked up in the mornin..

the 8 lug 15x7 rims for the sploder..(hmmm..I think a trip to work over the weekend will get them swapped)..



the bushing ends I got off the e-bay vendor..not too bad lookin..we'll see how they hold up...(and some cheapie heim ends for what-not projects..)


the boxes...kaylee's gonna build a fort..or somethin..

DB_1 said:

Looks good, got some different ideas there which is nice to see.
What do you have planned for the engine x-member? I need some ideas to ditch mine and build something new...that monstrosity gets in the way of everything

Click to expand...

yep..1 1/2 .095 wall tubing bent around the front of the old crossmember..it gains about 4in from stock...

I know a guy that did this..seems to work out well for him..boxed the frame rails too..

and a girl had this built from www.bbpfab.com

spent today grinding calipers for the 15's...and measuring for placement of the radius arms so they wont hit the tires at full lock...

gonna have black boogers for 3 days!!

welp...got the new radius arm brackets welded on..only took 3hrs...

edit...pix didnt load...

EDIT..and now the site is down..hold on a second..




lets see if THIS works..

Looking good. Although I can't see the last two pics you posted that are hosted at the ohio off-road site. The rrorc ones work fine.

well...got the old pitman arm off..and out of the way...got a lead on my front springs..and discovered to my JOY...the extended brakelines will work with the new FW 44...yippie...now to get tubing and the front end in..back brakes plumbed..shafts...steering..should be done around mid feb..hopefully..

new pix..35's loaded..gonna finish the arms this weekend..hopefully the springs show up...then steering and pan-hard bar...

rear brakes need work/lines..driveshafts..

Looking good dude! Keep the pics coming. I'm interested to see what you do for an engine x-member.

zainyD said:

Looking good dude! Keep the pics coming. I'm interested to see what you do for an engine x-member.

Click to expand...

Im gonna bend a piece of tube and attach it to the front inside portion of the old mount...

Looking badass!

got the arms done today..and the sterring mocked so I can move it..and figured out my track-bar mounting..

now onto the real steering..brakes..driveshafts.

actually...I might even go back out tonight and do my trackbar...

sweet looking rig man

got the parts for the panhard bar..

and its too frickin cold and wet in the barn to do anymore work today (I had to get some parts drug up from the spare parts pile..and its muddy..and a mess..and one axle was pissin me off...broke 2 ratchet straps..got hung up on my chickencoop fence...ended up gettin the crewcab out to pull it to the garage!!)

last week..and over the 3day weekend...

got the drivers side rad arm 90% done..still have to plate the area in between and then figure out the shock mount...



edit for finnished arm (minus shock tabs)

welp..trackbar is made...and installed on one end...still have to make a couple of braces for the frame end...(like these..I've seen to many frames crack at this point..and spreading the load really helps out!!) and bracket cleaned up a bit..

3/4 hole tractor 3rd link..

needs cleaned up a bit too...

Tony, you're making me look like a slack ass

oh wait...i AM a slack ass