M90 rebuild (rudy)

well figured i would start a new thread.just a quick background.did the whole build on my explorer but built it using stock head gaskets and head bolts.did it really as a safety net and i just couldnt afford head studs at the time.well to say the least i blew the head gaskets off from it wile i was in the mountains on a forum trip about two years later.

i picked up a 1994 ranger,its got the 4.0 OHV and is a 5 speed 2wd.the plan is to pull the motor out of the explorer and rebuild it.

this thread will basically cover the rebuild and build up of the new ranger.it will basically end up as a street race truck.ive named it Rudy so let the fun begin.


UPDATE
new motor specs
BORE: 4" JE asymmetrical pistons (custom over bore)

RODS: 6.058 Manley (longer rod)

VALVES: IN-1.8 EX-1.5 Manley heavy duty (.150 over)

Transmission:T5 hybrid from a 2006 Mustang and 93 Fox
HEADS: 93TM HEAVILY ported with custom brass guides and copper gaskets/O-ringed with ARP studs
CAM: 422 Comp cams with 988 springs and Toms custom lifters,push rods and 1.7 roller rockers
Complete blueprint and balanced internals
GM M90 supercharged with one 1" intercooler plates with ASP 8 rib belt conversion. .
pushing 16 lbs of boost with small shot of NOS
Running on E50
Dyno tuned by Dyno Tune Performance outa Virginia using SCT

old thread and pic
3800 M90 Build
ported and polished gm 3800 gen 2 m90
Water to air intercooled
port matched 76mm inlet and intake tube
mustang 75mm race tb
90mm maf
36lb injectors
255 fuel pump
sct 5bank dyno tuned
2.7" pulley 10lbs of boost!!

and the new 1994 ranger 4.0 OHV 5 speed 2WD with 115,000 miles on it.o and i only paid $1,000 for it:shifty_ey
RUDY

 

[jd4242]

These are the people I used to do all my custom mandrel bends, they did a good job and was very helpful. Wish I could have afforded stainless but im going to coat them all in ceramic flame proff paint.they down pipes and headers im wrapping in this new titanium wrap, said to be the new thing.

Bends
http://www.mandrelexhaustsystems.com/servlet/StoreFront

Wrap

http://www.ebay.com/itm/360931362020?redirect=mobile

 

[jd4242]

So still haven't put the exhaust on yet.buddy went on vacation so hopefully next week we can do it.ive put the pistons on hold for a bit till I can save up for it.all those parts put a hurtn on me and cost of machine work.im about to go on vacation myself so need to save for that..hopefully next month ill order them.

Meanwhile I've decided to start the body work and interior. Im filling every hole or handle in the truck.the tailgate and door will have e-poppers. My alarm has like 50 extra channels so figured id use them.ordered a handle relocate kit and stake hole fillers.I made my own for the gas door.

Im starting on the bed first.I ordered a roll pan of ebay and I see why everyone said not to.its a nice pan but was made to bolt on and have a 1/4" gap on each side to match the tailgate. I didnt want or like that so I cut 1/4" plates to match the ends and welded them to the pan.it fit tight after that BUT the tail gate has a slight curve or roundness to it.the pan was straight across, so the tailgate didnt match and hungover in the center. ....I took the tailgate and reshaped it.basically took a square tube and beat on it to flatten out the edge of the gate.it turned out pretty good, still hangs about a 1/4" over in the middle but its not really noticeable. .welded it all up and bondo it.I also cut a plate for the old gas door and welded it up, ran outa time to finish it but has a pretty good first coat.the truck was hit there so had to basically mud the whole area to smooth it out..

I ordered some racing seats from summit. I dont know how im going to mount them yet.probably end up cutting up the stock tracks.they come with slider and push button fold for rear access. They are black so thinking im going to dye that ugly blue carpet black!!! After they are in im going to start on the cage.o also ordered a set of 10" speakers to replace my 8" ones, needed a little deeper bass

Seats
http://m.summitracing.com/parts/SUM-G1159-2


Roll pan
http://www.ebay.com/itm/370867052183?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

Fill plates and handle relocate

http://www.ebay.com/itm/261124840330?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

http://www.ebay.com/itm/251302347038?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

 

[mr cribb]

Nice license plate. But officer it's just a v6.

 

[vroomzoomboom]

if your real picky about the gate hanging over what you can do is make a slice in the bottom of the gate the same length as the overhang then grab a chunk of 2x4 and a 3lb sledge hammer. lay the 2x4 on the gate, and smack it into shape. when you have it where you want it, weld the slice back up.

 

[vroomzoomboom]

oh, also are you going to take the stock tail lights out and fill them in?

 

[jd4242]

if your real picky about the gate hanging over what you can do is make a slice in the bottom of the gate the same length as the overhang then grab a chunk of 2x4 and a 3lb sledge hammer. lay the 2x4 on the gate, and smack it into shape. when you have it where you want it, weld the slice back up.

I really thought about that and figured I could get it close but it does still hang so ill probably do that when I move the handle and fill that hole

And no im gonna leave the lights.no way I can get away with that around here lol

 

[jd4242]

So got my 8" swapped out for my 10".had to cut the frame a little and then had to use rivits where the old handle bolts went.but wow what a difference. I still cant believe they sound as good as they do, cheap subs and basically no box!! Lol

Also got my seats mounted.I used the stock slider and everything. Was pretty easy honestly, they some how make you feel like you are sitting up higher but by measurement they sit lower..I dont have tilt wheel so its a PIA to get in and out, that will be add to the list nowdyed my ugly blue carpet black and looks 100% better..

Waiting on some parts to come in to finish the body work....

Old ugly carpet. .

 

[jd4242]

Anyone know what models come with tilt steering? ?will one from a first gen explorer work?



Edit
think I found my answer but what is different with the circuit? ?or maybe the OP didnt have cruise. .I did, removed it, but its wired for it

"""

any Tilt column from#
a)Ranger '89-94
b)Explorer '91-94
c)Navajo '93-94
d)Mazda B-series truck '93-94
e)Bronco2 '89-90

ALL Ranger based vehicles with tilt clumns were factory equipped with#
cruise control. that means there will be a difference in the wiring connector#
for the horn circuit

 

[jd4242]

Got my tailgate and old fuel door all done.swapping the handle was straight forward and easy..next to get the stake holes done.my other seat is finally coming in tomorrow so that on the list also..

 

[Dono]

JD, I didn't know you were so good with body work also. Looks great!

 

[jd4242]

JD, I didn't know you were so good with body work also. Looks great!

Thanks
OOOOOOOOOO im not!!! I HATEEEE it.those that do it well and for a living have a talent and are worth every dollar. ..it still needs some good touch up but this isnt final primer or anything. Just filling dents and holes

Lol I've got two herniated disc so this has been NO FUN at all..im actually at the docs about to get another MRI as we speak.lol

 

[Dono]

Be careful with that back! Geez. There's not much that can be done for that stuff.
That will haunt you for the rest of your life.

 

[jd4242]

Be careful with that back! Geez. There's not much that can be done for that stuff.
That will haunt you for the rest of your life.

Yea ive hurt it before but its never felt like this.I couldn't even walk.the ambulance had to drag me outa my bed..its been about two weeks now.they have me on all kinds of drugs thinking it was a muscle pull but I keep telling them its not.its being covered by my work so had to wait to get a MRI..:thumbdwn:

 

[4pointslow]

Title

JD, Get well soon!
Great work on that truck! Looks awesome.
I have to ask, how do you open the tailgate now?
Do you lift up on the tonneua cover to get your hand in there?
This is going to be one bad a** truck when it is done!

 

[jd4242]

JD, Get well soon!
Great work on that truck! Looks awesome.
I have to ask, how do you open the tailgate now?
Do you lift up on the tonneua cover to get your hand in there?
This is going to be one bad a** truck when it is done!

Thx.they are planning on giving me a shot.Hopefully that helps.

For now yea I just lift the edge and pop the lock for the cover, then I can get to the handle.I plan to put poppers on it also tho.

I just cant wait to get my new motor done.yall are making me jealous with all the new upgrades and mods.I think in the next week or two im going to throw my injectors in and put the sc on the stock motor.my tune should be very close and gonna run the smaller pulley (3.2) ..im just missing it to bad and kind of wanna see what it will add on the dyno, I just had the motor dyno so know what it did before..

 

[Turdle]

A lot of times the insurance delays the MRI hoping the injury will heal and look less like a ruptured disc. Ask me how I know. Get a fusion done as soon as possible would be my advice. I hope you find relief soon!

 

[jd4242]

A lot of times the insurance delays the MRI hoping the injury will heal and look less like a ruptured disc. Ask me how I know. Get a fusion done as soon as possible would be my advice. I hope you find relief soon!

Thx.man seems like its going around.lol they are hoping its not ruptured but know soon.its pinching a nerve they think in L5, I didnt have reflexes in my right foot/leg and the xrays didnt look good to them but noone said anything in the ER weeks ago when it happened! !

We are busy as crap at my work so I hired two people to help, ive been basically doing paperwork and sitting in a chair sanding on my truck...lol that parts nice if I wasnt in such pain

 

[mr cribb]

Oh man I know your pain buddy. Herniated disc's is what medically retired me from the Army.

There's not much other than a spine fusion or you deal with it. My injury goes from L3 to S1. The L3 blew out because it was compensating for the other two.

I am not a spinal fusion candidate, nor a surgery candidate, so I live with mine. Some days are better than others.

I can tell you when it's going to rain now. It sucks miserably because I'm only 34. I have been living this way for 8 years now.

Naproxen is the best for your stomach (according to my doctor), and see about a mild muscle relaxer. Don't take the pain pills, because they're addictive.

I wouldn't want anyone to live in constant agony. I hope you get something done soon. Good luck.

 

[jd4242]

Got my seats all done.I redid the brackets to make them sit about 2 1/2" lower.they fit nice and can easily be adjusted up some if need be..but wow what a transformation! !

Make some straps to go across

Cut all four of the welds separating the top slider from the bottom..

This is the part you cut off and dont need..

Then weld your straps to the lower slider and your done.spacers can be used when bolting the seat in to raise it..

Also got my stake holes filled.couple more dents and she will be ready for final bondo and primer dont need to show all four, you get the idea

 

[4pointslow]

seats

Those seats look awesome!
Are they light?
Comfortable?
Do the bolts that go into the bottom of the seat go into a metal frame?
Just curious of the seats construction.
2nd Gen Explorer seats leave a lot to be desired.