Ryan's F250/Explorer hybrid

*arsoul* · 04-21-2002, 10:56 PM

The master cylinder. Kevin posted a pic of the slave and the bracket we fabbed to hold it. We used a combo from a 84 BroncoII. The master had to be shimmed against the firewall so that the rod could meet with an Explorer clutch petal.

*arsoul* · 04-21-2002, 11:02 PM

This pic shows the mild firewall modifications we had to make. In order to make clearance for the valve cover, we had to push the firewall back about 2 inches. I glued it all back together with JB Weld (about 40 dollars worth!). We also had to push the firewall back about an inch to make clearence for the exhaust manifold.
I knew from the beginning that there would be no A/C, but I didnt know I would have to tear out the A/C condensor to fit the engine. As it turns out, when the heater is on, the hot air passes by the condensor into the dash. I wanted to keep heat, so I had to fab that blue triangle you see to get the hot air into the dash.

*arsoul* · 04-21-2002, 11:05 PM

Here's the steering shaft we made. I ripped a steering shaft from a mid 90s Windstar. I wanted its ujoints. I then mixed those with the end from the explorers origonal steering shaft and from the other end from the F-250s steering shaft. Those are some narly angles, but they are not as bad as the ones in the Windstar. We'll wait and see how the ujoints hold up.

*arsoul* · 04-21-2002, 11:11 PM

Here's a shot from the rear of the Dana60. Thats the rear rock light (there are a total of 3, you can see the back of the middle light pointing down towards the t-case). I used simple tractor lights for those.
Thats the Hooker muffler, I love the sound of it. Also, we just finished the ebrake. The paint wasnt even dry when I took the picture. We had to fab that wierd looking bracket for the cables. I tell you, it was a pain splicing the cable from the Explorer to the cable of the F-250.

*arsoul* · 04-21-2002, 11:14 PM

The rear bumper isnt installed yet. I'm putting up this pic to show the rear cargo container I fabbed up. Access will be from under the bumper, I'll make a little door for it later. I figure I can put a tow strap and winch gear in there. The box is tucked up between the rails of the tow hitch. If it gets eaten by a rock I'll then make the bottem of the box out of 1/4inch plate.

*arsoul* · 04-21-2002, 11:18 PM

Here's something I had not anticipated. It called for an extra trip to the hardware store. Matching up the gas filler tubes was done by using exhaust pipe reducers. The explorers tube is somewhere around 3 inches, and the F-250s tube is 2.25 inches. By the way, the F-250 fuel tank is 24 gallons. That should be enough with the 1barrel carb.

*arsoul* · 04-21-2002, 11:20 PM

Here's a pic of the front axle, from the front. You can see the front rock light tucked up there in the frame rail.

*arsoul* · 04-21-2002, 11:24 PM

A couple other notes:
I'm going to build a front skid plate out of 1/4inch plate to protect the radiator.
After getting the bumper and winch on, the front end sagged down a 1/2inch. I dont see how I can lower the front suspension anymore. There is only 6 inches between the frame and the top of the leaf pack. I guess this is how tall its going to be. After I get the rear bumper with the tire carrier on, and I let it settle, I'll reduce the rear blocks to level the truck out.
If I have trouble on the trails being tippy, I'll just have to build myself an exo-cage

Thanks for the use of your camera Kevin. Much better than the one I have available to me.

**Diff Whack Daddy** · 04-22-2002, 08:31 AM

I'm glad I ledt the camera as I am sure the rest of the followers of this thread are. I am impressed with how fast that thing is coming together.

jonny 5 · 04-22-2002, 10:51 AM

That's one sweet looking....uhhh.......eX-250. Get a comparision pic next to a stock F-250 and an explorer.

Let's see that thing in action!

*arsoul* · 04-22-2002, 09:36 PM

I need a rear driveshaft first....should have it in the next couple of days.

**Diff Whack Daddy** · 04-22-2002, 09:43 PM

Are you just going to have the original f250 driveshaft shortened?

*arsoul* · 04-22-2002, 09:58 PM

Yup. needs new yokes, but its otherwise good. upgrading to 1350 ujoints, making 48 inches long.

91'explorer 2wd · 04-23-2002, 06:21 PM

that is one bad TRUCK , can't wait to see that thing in a layer of mud.

*arsoul* · 04-24-2002, 01:26 AM

Kevin came over today just after I got my new driveshaft installed. We flexed the beast out a little. Keep in mind, I havent done any work to increase flex as of yet.
I guess the rock lights work pretty well.

*arsoul* · 04-24-2002, 01:27 AM

From the front, unfortunatly kevins camera took a crap.

**Flounder** · 04-24-2002, 09:00 AM

Is it me or is this project progressing at an incredible rate?? :-D

Clint · 04-24-2002, 07:49 PM

!!!!WEAK!!!!

espnfreak · 04-24-2002, 07:50 PM

i wasnt payin attention to this thread. That beast is incredibly awesome. Its huge!! congrats!

**Rick** · 04-24-2002, 07:53 PM

I thought you said you had 37s under there

04-21-2002, 10:56 PM	#121
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	The master cylinder. Kevin posted a pic of the slave and the bracket we fabbed to hold it. We used a combo from a 84 BroncoII. The master had to be shimmed against the firewall so that the rod could meet with an Explorer clutch petal. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:02 PM	#122
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	This pic shows the mild firewall modifications we had to make. In order to make clearance for the valve cover, we had to push the firewall back about 2 inches. I glued it all back together with JB Weld (about 40 dollars worth!). We also had to push the firewall back about an inch to make clearence for the exhaust manifold. I knew from the beginning that there would be no A/C, but I didnt know I would have to tear out the A/C condensor to fit the engine. As it turns out, when the heater is on, the hot air passes by the condensor into the dash. I wanted to keep heat, so I had to fab that blue triangle you see to get the hot air into the dash. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:05 PM	#123
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Here's the steering shaft we made. I ripped a steering shaft from a mid 90s Windstar. I wanted its ujoints. I then mixed those with the end from the explorers origonal steering shaft and from the other end from the F-250s steering shaft. Those are some narly angles, but they are not as bad as the ones in the Windstar. We'll wait and see how the ujoints hold up. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:11 PM	#124
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Here's a shot from the rear of the Dana60. Thats the rear rock light (there are a total of 3, you can see the back of the middle light pointing down towards the t-case). I used simple tractor lights for those. Thats the Hooker muffler, I love the sound of it. Also, we just finished the ebrake. The paint wasnt even dry when I took the picture. We had to fab that wierd looking bracket for the cables. I tell you, it was a pain splicing the cable from the Explorer to the cable of the F-250. Attached Images __________________ Ex-250 Ryan Last edited by arsoul; 04-21-2002 at 11:26 PM.

04-21-2002, 11:14 PM	#125
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	The rear bumper isnt installed yet. I'm putting up this pic to show the rear cargo container I fabbed up. Access will be from under the bumper, I'll make a little door for it later. I figure I can put a tow strap and winch gear in there. The box is tucked up between the rails of the tow hitch. If it gets eaten by a rock I'll then make the bottem of the box out of 1/4inch plate. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:18 PM	#126
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Here's something I had not anticipated. It called for an extra trip to the hardware store. Matching up the gas filler tubes was done by using exhaust pipe reducers. The explorers tube is somewhere around 3 inches, and the F-250s tube is 2.25 inches. By the way, the F-250 fuel tank is 24 gallons. That should be enough with the 1barrel carb. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:20 PM	#127
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Here's a pic of the front axle, from the front. You can see the front rock light tucked up there in the frame rail. Attached Images __________________ Ex-250 Ryan

04-21-2002, 11:24 PM	#128
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	A couple other notes: I'm going to build a front skid plate out of 1/4inch plate to protect the radiator. After getting the bumper and winch on, the front end sagged down a 1/2inch. I dont see how I can lower the front suspension anymore. There is only 6 inches between the frame and the top of the leaf pack. I guess this is how tall its going to be. After I get the rear bumper with the tire carrier on, and I let it settle, I'll reduce the rear blocks to level the truck out. If I have trouble on the trails being tippy, I'll just have to build myself an exo-cage Thanks for the use of your camera Kevin. Much better than the one I have available to me. __________________ Ex-250 Ryan Last edited by arsoul; 04-22-2002 at 12:34 AM.

04-22-2002, 08:31 AM	#129
Diff Whack Daddy And the Roll Over Posse! Under the Hood Moderator Mount Vernon, WA 1st Gen XLT 4dr Join Date: Feb 1999 Posts: 3,741 Vehicle Specs	I'm glad I ledt the camera as I am sure the rest of the followers of this thread are. I am impressed with how fast that thing is coming together. __________________ Mount Vernon, WA Keep the Rubber Side DOWN!! OHV: 1st Gen-XTREME Tow/Chase Vehicle: Banks powered F-350 SuperDuty w/ camper Commuter: 08 Ford Focus SES(35 mpg, SYNC system) Projects: House, better on board air. Kevins Big Model and list of mods

04-22-2002, 10:51 AM	#130
jonny 5 Wannabe Elite Explorer Seekonk, MA 02771 (home), N. Dartmouth, MA (college) '98 XLT SOHC Join Date: Oct 2001 Posts: 919 Vehicle Specs	That's one sweet looking....uhhh.......eX-250. Get a comparision pic next to a stock F-250 and an explorer. Let's see that thing in action! __________________ Westin Safari Bar, Bugdeflector II, Lund Windjammer, KKM, Edelbrock ISA shocks, custom painted vinyl.

04-22-2002, 09:36 PM	#131
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	I need a rear driveshaft first....should have it in the next couple of days. __________________ Ex-250 Ryan

04-22-2002, 09:43 PM	#132
Diff Whack Daddy And the Roll Over Posse! Under the Hood Moderator Mount Vernon, WA 1st Gen XLT 4dr Join Date: Feb 1999 Posts: 3,741 Vehicle Specs	Are you just going to have the original f250 driveshaft shortened? __________________ Mount Vernon, WA Keep the Rubber Side DOWN!! OHV: 1st Gen-XTREME Tow/Chase Vehicle: Banks powered F-350 SuperDuty w/ camper Commuter: 08 Ford Focus SES(35 mpg, SYNC system) Projects: House, better on board air. Kevins Big Model and list of mods

04-22-2002, 09:58 PM	#133
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Yup. needs new yokes, but its otherwise good. upgrading to 1350 ujoints, making 48 inches long. __________________ Ex-250 Ryan

04-23-2002, 06:21 PM	#134
91'explorer 2wd Wannabe Elite Explorer McAllen, TX '92 XLT 4x4 Join Date: Mar 2001 Posts: 227 Vehicle Specs	that is one bad TRUCK , can't wait to see that thing in a layer of mud. __________________ '02 x rims 3 chamber flows w/no cat k&n filter that's worthless 33" wrangler at/s b/lift, still working on her...slowly but surely

04-24-2002, 01:26 AM	#135
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	Kevin came over today just after I got my new driveshaft installed. We flexed the beast out a little. Keep in mind, I havent done any work to increase flex as of yet. I guess the rock lights work pretty well. Attached Images __________________ Ex-250 Ryan

04-24-2002, 01:27 AM	#136
arsoul Elite Explorer Monroe, WA 94 Ex/79F250: X250 Join Date: Oct 1999 Posts: 874 Vehicle Specs (Original Poster)	From the front, unfortunatly kevins camera took a crap. Attached Images __________________ Ex-250 Ryan

04-24-2002, 09:00 AM	#137
Flounder Elite - Owns 10,000 Marbles Pennsylvania '04 Sport Trac Join Date: Oct 1999 Posts: 6,544 Vehicle Specs	Is it me or is this project progressing at an incredible rate?? :-D

04-24-2002, 07:49 PM	#138
Clint Wannabe Elite Explorer Mesa ,AZ 91 sport Join Date: Oct 2000 Posts: 678 Vehicle Specs	!!!!WEAK!!!! __________________ 7" of total susp. lift .... 33's blah blah blah

04-24-2002, 07:50 PM	#139
espnfreak Wannabe Elite Explorer Elgin, IL '99 Maxima SE-L 5spd Join Date: Feb 2001 Posts: 3,820 Vehicle Specs*	i wasnt payin attention to this thread. That beast is incredibly awesome. Its huge!! congrats! __________________ Mechanical Engineering @ Purdue University 1996 Ford Explorer - TOTALLED Life's A Garden - Dig It '99 Maxima SE-Limited 5 spd - 42,000 mi, fully loaded, silver

04-24-2002, 07:53 PM	#140
Rick Admin Pumpkin Pilot Wayoutin, Aridzona '93 XL Join Date: Feb 1999 Posts: 27,246 Vehicle Specs	I thought you said you had 37s under there __________________ Rick Horwitz, AB7FH "Serious Exploration's" Admin Rick's '93/'98 Explorer "The Great Pumpkin" Dodge Dart 512 Resto/Race 10.29 @ 129 2004 Mustang Mach 1 2003 Dodge Ram/Cummins Dually