5.0 Full width SAS build

[EBEX99]

I've had my ex for just about 3 years, and its been a never ending project. I've been collecting parts for the sas project for a couple months and i almost have everything. Which means the IFS will be cut out very soon . My plans are to run a full width Dana hp44 out of a 79' fsb. I bought it from a buddy, already geared with hardened shafts and a limited slip. Not too bad for $500. For the rear i will be running a full width 8.8 from a 96' f-150.
Specs:
1999 5.0 Eddie Bauer Explorer (4406 transfer case swap already complete) 308,x.. miles
4.56 gears
Dana hp44 full width fsb (lsd for now)
hardened shafts
ford 8.8 full width
soa conversion for rear, 7" anti wrap leaf perches
d.o.m. extended radius arms with 1.25 heim joints
7 degree c bushings
ballistic fab adjustable coil buckets
5.5 lift early bronco coil springs
1st gen explorer steering box
full 7/8 heim/dom steering
Ram assist steering (later to come)
haven't fully decided on the rear locker (lunchbox)
warn premium hubs
15x10, 5x5.5 black d window steel wheels
36-37 inch tires

How she sits now

fresh hub rebuild, brakes and new warn premium hubs installed

Dana 44 with 35s that came with the axle (rollers/mockup tires)

A little size comparison lol

Getting the dom setup for steering

Some goodiez

8.8 getting cleaned up and stock leaf perches and shock tabs cut off

Welded the axle tubes on the 8.8, but ran out of wire with like an inch to go lol

i will update pics and progress as it comes, when taxes get here ill have most of my parts then it comes down to finding the place to do it, and transportation while the ex is down for the sas build.

 

[EBEX99]

Haven't Posted in a while been working on the sas project for about 7 weeks now. Its driving now just need a front drive shaft for 4x4. tires are first on the list, followed by new coil springs because the current ones are completely too stiff. now time for the good stuff, pics lol

 

[Przybysz]

I want your bumper!!! Looks good!

 

[EBEX99]

say goodbye to the ifs!

All cleaned up ready to plate the frame

i decided to tackle the rear axle first. Soa with all new perches, plates and u bolts. this way i could determine the ride height so i could match the front.

(maybe i should make a hoovercraft)

Ruffstuff spring plate and ubolts, along with barnes4wd 7" anti wrap perches (beefyy)

Installing the usa standard 4.56 and doing a complete rebuild while im in there

4.56 and spartan locker installed

Rear axle done, the front is just sitting there but this should be ride height. pretty happy with the height

So, my original plan was to use a first gen steering box. because FORD! unfortunately i could not get the ford box on the inside of the frame with the 5.0. i installed a oil filter relocation adapeter, but the box would not clear the adapter with the inside of the frame being plated. so i opted for a ifs yota box. found one on craigslist and got fabbing. the frame is plated on both sides and the bolt holes are sleeved.

i used a hanger bearing from off of the work truck (commercial laundry parts to the rescue again!) this is to reduce flop and play in the steering shaft. still kinda need one at the top towards the firewall but it works for now (not welded down yet)

the stock toyota pitman arm was used, i removed the fatory balljoint style end on it and welded a 3/4 inch sleeve in the pitman arm for the 7/8 heim joints and misalignments

with the draglink set, measuring angles for the track bar.

Frame track bar mount

the track bar and draglink are dead on with each other. 6 degrees shouldnt have any bumpsteer.

cutting dom tubing for custom radius arms with heim ends

bungs welded in

Finished radius ams

Attatching the radius arm mounts to the frame

the track bar axle mount is seen here

Ballistic Fab adjustable coil buckets welded down. i highly recommend these. great product and somewhat coil over adjustablity for coil prices lol 99.99

all steering links and track bar done

ride height on bald 35s

little jack flex lol

i ended up putting the oil filter right on the block out of harms way of anything

Better pic of the coil buckets, plum bobbing the shock towers

Lower shock mount

shocks.. nomz nomz

FIRST TEST DRIVE

Baby flex

Starting the new transmission cross member to clear the front driveshaft

I broke off one of the studs on the trans mount (impact) i should have replaced the mount then cause it bit me in the butt later lol

Driveshaft shortened, 4.6 f150 shaft

Driveshaft and new transmission crossmember installed. now were in commission!

Testing the front driveshaft.
F*#K your couch!

i decided to go with super swamper ssr radials. 37x12.50x15

New meat installed.

Im happy i went with radials being i drive alot on the road and highway. i can do 80mph comfortably with these tires and this set up. only running 2100 rpms at 70mph. im pretty happy with the gear range. still has alot of torque off road. dead pulled a f150 through some nasty stuff with no problem. maybe one day when this becomes a toy only ill re gear it lower.

ohhhahhhh

daily florida storms

Clay mine shake down ride. super stoked with the way she performs

i havent yet, but i made a little more tire clearance with the ole trusty bfh. dont wanna slice up the brand new ssr's

First long ride. meet up with some guys and went to ocala national forest.

So after driving it for about 3 months, about 3,000 miles, and a few wheeling outings. its everything or more than i wanted, coulndt be happier with the project. i do need a few things including bumpstops, limit straps, redo my y pipe for more clearance, raise the gas tank, and clock the transfercase for a future belly up pan.

 

[dersch6221992]

what is your roof line height after the sas?