explorer upgrade

[whitetrashfab]

Well after my last axle failure (a split bearing hub) I figured it was time to start looking for something better. After I switched to Nitro axles and joints in the 44 my axle problems have been few and far between but I cant leave well enough alone... I could just switch to drive flanges and hope that my ring and pinion arnt my next weekest link... or I could go to 60's. I have broken lots of axles, universal joints, one ring and pinion, 3 warn and two stock ford hubs, one wheel hub, and riped one spindel tube off on my 44. I have also added alot of wait with my exo cage, bumpers, tools and spare parts that I drag along with me that dont help my problem. So the other day I bought a king pin dana 60 out of an 89' f350 and today I got a rear disc dana 60 out of a 00' econoline e350 van. I plan on cutting them down and installing them under my exploder, the plan is to have them in and ready by memorial day for a trip to the naches. I will try to take some pic's along the way to share with everyone. I already have the front striped, the short side notched, and I ordered the james duff weld on wedges. I should have the front cut down by the end of next week... this "should" be a fun build... and a huge waste of $$$$

 

[whitetrashfab]

Thanks Forrest... 89' dana 60 HP KP for $750 devivered to my work

 

[jrgaylor]

If you hurried you could be done for a trip to Moab

 

[whitetrashfab]

I thought about Moab but I figured I could do alot of local wheelin trips for the same amount of money and alot less driving (that and getting that much time off work is hard for Becky and I). I WILL make it to Moab one of thses days....

 

[whitetrashfab]

I did some cutting tonight

 

[whitetrashfab]

cut the read also

 

[whitetrashfab]

I was suprised that the van dana 60 was made with two different driveshaft bolt patterns drilled in it, the smaller of the two is the exact same as my explorer driveshaft. I also got some stuff from james duff the other day.

 

[whitetrashfab]

Got some more done over the last few nights... A friend of mine loaned me his alinement bar so I narrowed the rear. I turned the spindles true on a lathe and hand ground the weld-prep on the axle side after I made my final cut. I TIG welded the root pass and hot pass and used the MIG to finish weld out then I blend ground everything smooth when I was done.

 

[whitetrashfab]

Frone end cut down from 69.25 to 59.25, the same as my early bronco dana 44.

 

[whitetrashfab]

Got the rear finished last week. One side was right on with the alinement bar but the other ended up a little off after welding. I put some heat to it and it is almost there, I will try a little more but for what I do with the rig it dosent have to be exact. I had a hard time trying to figure out how narrow to make the rear. Most rigs the rear is a few inches narrower then the front to help steering but I think that all goes out the window when your running a spool anyway so I made it the same as the front. That will keep me just under the stupid 80" trail width with 10" wide wheels. Sounds like I have my tires and wheels sold so I will pull my axles out soon and start the swap.

 

[fastboxR]

lookin good. you need to put some 40s under that thing or maybe some 42s.

 

[whitetrashfab]

update... I had had some problems with how the front axle was fitting so I widened the front and rear to 63" wms (I had cut it to 59 before) and made up for the added legenth by going to a bigger rim offset. I bought 5 new 39.5 Iroks that Im going to stuff under it when the axles are finished. I am waiting for them to finish cutting my beadlock rings so I can getthe rims welded up and mount the tires. My axle shafts showed up today from dutchman so theres one more thing taken care of.

 

[whitetrashfab]

I got some stuff done

 

[NWOff-Roader]

Looks like a great build, subscribed.

 

[fastboxR]

Can you open and close your doors? It looks like you have a bar across the door. Just wondering if you get in Dukes of Hazard style... the build is lookin awsome by the way!

 

[whitetrashfab]

I am still working on the door bars but they are bolted to the door and open/close with them. I thought I would give them a try with my new doors... the last ones got so bad I couldnt get new glass to fit in them.

 

[jrgaylor]

What type of mount for your track bar?

 

[Diff Whack Daddy]

I am still working on the door bars but they are bolted to the door and open/close with them. I thought I would give them a try with my new doors... the last ones got so bad I couldnt get new glass to fit in them.

Looking forward to possibly copying your design on that. Just gotta find another passenger door first.

 

[jrgaylor]

I know where there is 4 of them Kevin

 

[fastboxR]

Yeah if you get a decent design going on those doors I would like to copy you too. Post more picts of that design if you could and more picts of the axle project.