Dannyboy's Re-Registry

What better time than now to do this.

Here is my old 94
http://www.explorerforum.com/forums/showthread.php?t=100935

Just when my transmission crapped out again, I saw my current 91 for sale on this forum. Joe (Lilmule) owned the truck since new and moved to Milwaukee. When I got this truck I had no clue what I was getting myself into. Honestly, I purchased the truck for the glass fenders and C4/C5 transmission setup. I didn't want to deal with TTB, didn't know who "Autofab" was and didn't like that it was spring under and had some 9" axle that I knew nothing about. Here was the plan, combine these 2 trucks, solid axles, updated glass, C4/C5 tranny, 37" swampers, and ditch the blue truck.

Luckily for me and this truck, I didn't have time to start parting it down. I took it out on a few rides, fully rusted out and couldn't believe the "shalackin" I could put into this truck. I spoke with Joe on the phone a few times over the first year and he kept going on about how great this setup is but never really knocked my solid axle idea or told me what to do. I did start to see that some serious money was spent on this rig the first time it was built.

When Joe mentioned his bill was in the 5 digit numbers at various places like Autofab, Currie/Mogi etc, I realized that I needed to do some more digging into what I had gotten myself into.

Disappointed my 94 that had nearly $30,000 into over the years was sitting dead with transmission parts in a box in the backseat, I researched what I had. I realized that the blue 91 was the truck to move forward with, XL over a Limited means less issues, power features to short out and it had some serious potential. I parted down my 94 and laid it to rest.

The for sale ad even said "Needs TLC, after that..."

and this brings me up to speed.

I ran this truck for a while, my avatar photo was taken without spending $1 on this truck, I couldn't belive taking a truck that was sitting could handle this abuse. This little thing was just a machine.

Then I went to Truckhaven and it was pointed out by other members that I had some work to do, a shackle was nearly rusted through, radius arm bushings were toast, etc. I didn't care, I have a trailer and a tow rig...this trip it paid to have them. I was running a wash and snapped the passenger side u bolts, puncturing the tire and leaving the truck not driveable. I don't even think a trail repair would have gotten me to drive this out.

I still got a good weekend of wheeling out of this truck and still had the attitude that I could leave it behind if something happened to it for how cheap I bought it.

Still considering the Dana 44 I have sitting at my house, I decided that I didn't want to give up the speed. I visited Autofab while in San Diego and John was a very cool guy for discussing a truck he built probably over ten years ago. It was at that point I decided to go forward with the original intention.

One trip to Truckhaven with some new updates such as 33x12.50s instead of 33x9.50s, new spring pack to replace the original 11 leaf spring under pack (which raised the rear of the truck nearly 5" from the tired pack), new brakes, auxilay fuse panel, the bumper from my 94 got me excited making it look like a whole new truck.

It was at this point I got bit bad by the bug. I needed new shocks, the rear was just too bouncy, I was going fast and am madly in love with the lady who loves to ride shotgun so now 2 lives needed to be protected and lots of stuff needed to be fixed to keep up with this speed.

Well, 6 months in the fab shop, the truck has just had it's first run with the "new" setup.

So here is the breakdown

Engine
Ford 4.0
KKM filter
stainless intake
hypertech chip
headers
exhaust

Transmission
C5 3 speed built by Mogi Enterprises with all C4 internals
reverse valve bodied (an auto but you need to manually shift)
Art Carr shifter
B&M tranny pan

Transfer Case
Stock pushbutton transfer case (button in a not-so-stock dash)
spaced back since C5 tranny is much shorter than stock, retaining stock front driveline length

Front End
Dana 35 TTB, AutoFab kit (the $3600 kit before shocks!!!) inlcudes extended radius arms, tranny crossmember, triple shock mount (1 behind, 2 in front) currently running Rancho 5000s but 3 of them keep it in control
16" of wheel travel approx 6" of raised height over stock
4.56 gears-no locker (don't want one)
warn manual hubs
5/8" wheel studs
limiting straps
"Winter" mods on inner axle shaft and passage

Rear End
Ford 9" built by Currie, fully trussed
4.56 gears w/ Detroit quick lock
Disc brakes, Wilwood 4 piston calipers, 2 piece rotors (see writeup)
5/8" wheel studs
Valley Spring Service 11 leaf spring under leaf pack
Total Chaos low profile u-bolt retention plates
King 3.0 16" travel triple bypass piggyback shocks
Aftermarket Shackles
Wilwood brake proportioning valve

Wheels/tires
I've ran several setups, currently running 35" BFG Krawlers on 15x10 steel wheels.

Other Exterior
Perry's 2000 conversion front end, 6" pull fiberglass
4 pin removable fiberglass hood
autofab prerunner front bumper
Dannyboy's designed rear bumper/2" receiver
Rock sliders
2-8" 130 watt driving lights
4 rocklights mounted 2' behind each wheel

Cage

HUNTER OFFROAD custom built roll cage-www.hunteroffroad.com
*all interior gutted for tight fit
*in-cargo shock mount for King shocks
*4 bucket seats incorporated and tied into cage
*ties into frame in 6 positions
*ties into body in 16 positions
*spreader bars
*A-pillar support (required windshield removal)
*1.75" steel and 1.5" (approx 130 feet total)
*Hi-lift Jack mounts, spare front/rear driveshafts, shovel, fire extinguisher mounts

Other work by Hunter Offroad
* removable Aluminum dash assembly
* custom built door skins (required with cage side support tubework
* hood pins for 4 pin removable hood

Interior
4 Corbeau bucket seats
4 Crow 5 point wrap-around harnesses
Auto Meter instrumentation gauges (Tach, Speedo, Oil pressure, Water, Fuel, Voltage, Transmission Temp) see writeup
12 Position Auxiliary fuse panel (see writeup)
Kenwood Receiver
Sirius Stiletto dash mount
Garmin Extrex Legend dash mount
CB radio
Full Recovery & Safety Gear + tools, parts

Here is my 3 step process to access all tools/cargo until I get a tire carrier of some sort built
tools/camping chairs/spare parts safely secured

Spare fluids in tote that securely fits under shock mount.

Tire just barely fits with 10PSI

Not sure where to list this, but I installed my Willwood proportioning valve to get the rear braking under control, can adjust front/rear brake distribution from the drivers seat

ROCK ON! Thanks for looking.

 

[Diff Whack Daddy]

Hell yeah, definately the bass boat sparlky silver. We can come up with some really cool CB call signs with that paint scheme.

 

[explornj]

i vote wedgewood blue

 

[Dannyboy]

The wait is over, time to get this pig running again.

and the new shoes got on the front so I could get my jackstands back! It's a tight fit for sure.

Going to have to figure out some major fender trimming on the rear of the front fenders!

 

[Dannyboy]

Well, I FINALLY have the rear brakes fixed from the Moab incedent. I basically was starting from scratch on a rear disc brake conversion with the exception of the rotor. Still crossing my fingers that the rotors I scored at the swap meet will be working or else it's another couple hundo for the wilwood dynalites.

Also had to cut out the bushings out on my rear stabilizer arms and replaced them (turned out it was an hourglass shaped shock bushing in there I was looking for). So now my 9" rear end isn't stuck to the truck and can be completely removed if the need be.

That means tonight I'll be bleeding the brakes and moving the truck into a better position to pull the engine.

I got my hands on a hoist so there is no longer a 4.0 V6 sitting on my tailgate. I can already tell there is going to be an issue pulling the exhaust manifold on that thing as it wanted to strip the bolt so I started away with the PBlaster

 

[R.J.]

Jealous of those tires!!!!!

As for clearance, take a grinder to the fender. You probably have two bolts holding the lower of rear fender, trim it down to one bolt. Next take a little sledge hammer and bend the seem/lip on the firewall part down

 

[Turdle]

Well, now there you go.

the engine stand holds up the engine, not the other way around. Just saying.

Now it is time to get dirty. Dirty Dan the engine man. You'll figure it all out I am sure.

 

[Dannyboy]

LOL, in case you didn't see in the Truckhaven thread I thought if I dropped the wheels/tires off the super duty it would lower the stand to the ground, turns out I'm still a foot in the air but I did manage to get in a needed tire rotation.

Is there a good thread around anyone knows about with a step-by-step R&R engine? If not at the snails pace I'm going it may not be a bad time for a writeup.

 

[Dannyboy]

IT'S ON THE TRAILER AND BACK FROM THE FIRST RUN IN THE DESERT IN 6 MONTHS!!

no pics or videos yet, heading out in an hour to meet up with Brad as he is testing the SDHQ trophy truck so I'll save the pics for what I take today!

 

[Turdle]

How is it running now?

 

[Dannyboy]

Truck ran well,

it wasn't pretty and smoked for a little bit.

but got it done

but not quite as good as this thing, I was doing about 55 in the rough stuff where he hit 92.

I was pretty excited when all of Brad's buddies commented on how suprised they were at how well the explorer rode.

 

[Dannyboy]

oh yeah, but I am not catching 2nd gear very often, it sticks in first.

 

[Tbars4]

..Right on Dannyboy..

..And fenders are over rated anyways...:

 

[Diff Whack Daddy]

And grills just block air flow to the radiator

 

[james t]

It looks pimp with the new treads on it.

 

[Lilmule]

OMG! Big enough rubber??
I'm surprised that you haven't torn up the rear wells.
Time for the other bedsides.
Looks like fun! I'm glad that you're having fun!
Joe

 

[Dannyboy]

Joe, I've seen you viewing this thread lately!

The new tires are great, they actually clear the rear just fine and only catch the inside of the wheelwells at an offcamber bounce at higher speeds...with 4 guys in the truck.

 

[carlover]

nice, looks good. at least youre getting to use and have fun with it.

 

[Dannyboy]

well, since carlover was the last guy to post, I figured I'd carry on like his style and post of some really bad cell phone pics.

The BFH and some cutting got the fenders in a postion to keep the Krawlers off of the fenders.

Boy, this truck is sure getting ugly, at least there's enough other distractions that you won't see how hacked the front fenders are. It looks worse in the pictures but I did remove a huge portion and got a tab welded on to support the fender (sicky prerunner status brah)

It's sure not as pretty as it used to be, but it's a lot more fun.

 

[section525]

Hmmm....

 

[Dannyboy]

Truck wasn't grabbing 2nd gear, I knew the trans was cooked from a few instances of it getting hot when I had the flex-a-lite fan in place.

Took it to a buddy, he had a blast working on the truck, said everything in the trans was cooked to a crisp. All new internals went in with a full rebuild and I'll have it back later today. Got an amazing deal paying green backs.


If you didn't see my other thread, this damn truck is heading back to Wisconsin! We're moving a week from tomorrow.

I will be entering in tough trucks in March http://www.amptour.com/2010_march_lacrosse.php