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'93 Sport Expo/ trail rig build

Discussion in 'Modified 1991-1994 Explorers' started by Dzrtcj7, August 30, 2016.

^^Searches ExplorerForum.com^^





  1. WormsExplorer

    WormsExplorer Elite Explorer

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    WOW That looks really clean.
     
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  3. Dzrtcj7

    Dzrtcj7 Member

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    Winch couldn't have for any better Everything looks so clean and tight, I'm having doubts about adding an upper tube.
    KIMG1713.JPG KIMG1714.JPG
     
  4. 410Fortune

    410Fortune MUD SEASON 2.0 Staff Member Moderator

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    perfect!!

    are those cough cough auto hubs????
     
  5. Dzrtcj7

    Dzrtcj7 Member

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    Haha, ya those are still auto hubs on there. They're only staying until the D44 knuckles go on, which should be shortly after our Thanksgiving snow run.
     
  6. WormsExplorer

    WormsExplorer Elite Explorer

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    That looks awesome. Love how it all turned out.
     
  7. Dzrtcj7

    Dzrtcj7 Member

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    Did a little bend test to verify that I don't need the top bar to support the outer wings of the bumper. Got zero deflection. I'm good with that!

    KIMG1716.JPG

    Self etching primer

    KIMG1718.JPG

    4 coats of Rust-Oleum Satin

    KIMG1719.JPG

    Finalized relocating the solenoid box to the core support and extending the wires for the controller plug. Ran the main wires through a grommet in the core support to go to the battery.

    KIMG1721.JPG

    KIMG1716.JPG
     
    Last edited: November 24, 2019
  8. Dzrtcj7

    Dzrtcj7 Member

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    All done! Just in time to go play on Thanksgiving weekend!

    KIMG1724.JPG KIMG1722.JPG KIMG1726.JPG
     
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  9. 410Fortune

    410Fortune MUD SEASON 2.0 Staff Member Moderator

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    very very very nice!!
    I wish I had a lounge area in the shop......it has always been one of the goals but so far the space reserved for couches always gets used up by more parts!!!!
    Now go snap one of those auto hubs maybe you can take out a turkey :)
     
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  10. WormsExplorer

    WormsExplorer Elite Explorer

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    Beautiful Work sir. I really wish I had the skills to build something like that. I need something like that for My Ex. :)
     
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  11. Dzrtcj7

    Dzrtcj7 Member

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    Thank you!

    When I got this shop I made a point of planning and setting it up completely before starting my first project. Don't get me wrong, every other square inch is full of tools and shelving. I just picked up a so press that has no home yet. But ... The couches stay!

    I see popping a turkey as a good thing; i get a turkey and a reason to expedite my D44 knuckles!
     
  12. Dzrtcj7

    Dzrtcj7 Member

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    I really appreciate the compliments. Honestly, I can't claim a whole lot of skill in doing this kind of fab work. To me, it's problem solving and taking the time get it right. Skill comes in getting it right the first time, and I'll be the first to admit, I don't get everything right the first time!
     
  13. timtimtimajim

    timtimtimajim Elite Explorer

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    Looking awesome!

    You're giving me ideas... particularly the fact that I want more lift height now. I guess having a twin is a bit of a curse:D
     
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  14. Dzrtcj7

    Dzrtcj7 Member

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    This will do until I can build my back bumper ... KIMG1728.JPG
     
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  15. Dzrtcj7

    Dzrtcj7 Member

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    Happy Thanksgiving everyone, we're headed for the mountains! KIMG1731.JPG
     
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  16. Dzrtcj7

    Dzrtcj7 Member

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    Had a great weekend with the Explorer! Temperature in camp Saturday morn was 1 degree! We met up with our old wheeling club for our annual Freeze Your Buns run up Little Naches outside of Yakima WA. Tradition is to go to the lookout at Raven's Roost. Some years that takes all day. This year there was only about 10 inches of fresh at the top. Along the way we picked up a nice little Christmas tree.

    After the run to the top we ran the lower portion of the Kayner Flats trail which had some hill climbs that the snow definitely made challenging. My old bald BFG AT's effectively made the Ex a Zamboni glazing the fresh snow in to packed ice. I made it everywhere, but with each passing rig the hills got tougher. Total carnage was 2 broken Jeep JL wheels (both on the same rig, at the same time), and a broken front driveshaft in a IH Scout.

    The Explorer was flawless! It was certainly nice having a cab and heat. My wife and little man appreciated it!


    FB_IMG_1575341857588.jpg FB_IMG_1575341831487.jpg FB_IMG_1575341865513.jpg FB_IMG_1575341876488.jpg FB_IMG_1575341882981.jpg KIMG1733.JPG KIMG1732.JPG
     
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  17. WormsExplorer

    WormsExplorer Elite Explorer

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    Looks like you all had a great time. about 6 ish years ago We did a Black Friday run. Was a lot of fun.
     
  18. Dzrtcj7

    Dzrtcj7 Member

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    Here's a video made by one our good friends who went on the run with us. He's definitely not afraid to wheel his new Jeep JL!

     
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  19. 410Fortune

    410Fortune MUD SEASON 2.0 Staff Member Moderator

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    how the heck do you break two wheels? Are jeeps just begging to throw parts at the ford or what?
    I will watch the video! Looks like fun, glad the sport did well she looks awesome!
     
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  20. Dzrtcj7

    Dzrtcj7 Member

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    Tear down of the D44 has started. One valuable lesson learned for anyone sourcing D44 parts; 95-96 D44 TTB's used a spindle/ seal/ hub that is different from all others. It's common (as in with my parts axle) for people to use incorrect seals, which leads to water and rust in the hubs/ bearings. It's important to know that replacement 96 style spindles are not available, nor is the hubs. If you ruin a spindle you have to swap spindle/hub/ seals to the 91-94 style.

    My spindles aren't great, they have quite a bit of corrosion, but they should clean up ok.

    Also note the 5 bolt pattern of the spindle. I know there has been talk of swapping late model D44 spindles on to D35 knuckles. I'll see what that looks like when I tear down my D35.

    Here's the comparison of D44 spindles from year to year:
    Screenshot_20191208-123115.png

    Here's my knuckle, spindle and hub. Note the extra shoulder on the spindle

    KIMG1742.JPG
     
  21. Dzrtcj7

    Dzrtcj7 Member

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    Welp, one of my spindles is junk. Now I get to go through the process of either finding a used one, or swapping my hubs and spindles to the older version KIMG1744.JPG
     

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