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My 2nd gen ex SAS

Discussion in 'Solid Axle Swap Registry' started by trogg, February 12, 2010.

^^Searches ExplorerForum.com^^





  1. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    so after a long time, money burning a hole in my pocket, and the devil on my shoulder..I went ahead and cut up my explorer.
    I started out with 2 dana 60's..one was a full float with brackets, 4.10's and stupid drum brakes.
    I went ahead and took the ring and pinion out of that and set the rest aside for a rainy day.
    Then I got my dana 60 housing, which is a semi float 5x5.5 pattern axle with no brackets, carrier, or gears.
    i rebuilt the whole thing and stuffed in the gears.[​IMG]
    after that part was all finished, I went out and got a set of ballistic fab GM caliper brackets and calipers, also I got the old axle out and thrown aside [​IMG]
    Then the new axle was all ready to be put in..so I switched the springs around in the rear to give me a little extra departure.[​IMG]
    heres one with the 37" claws up [​IMG]
    [​IMG]
    all this hard work made for a tiring day..Lets have some fun and add some bling
    [​IMG]
    the next day was spent cutting..and cutting..and cutting. then somehow we wound up with this!
    [​IMG]
    ..
    its finished now but I'm tired and going to bed. Will write more later:salute:
     
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  3. MEANEXPLODER

    MEANEXPLODER Active Member

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    is that a d44 in front? nice job dude
     
  4. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    yes it is! thanks for the compliments! final pictures and some more build pix to come ASAP
    btw. this thing is a blast to drive. I had it going 70 down the freeway no problem!
     
  5. peanuttbutterman

    peanuttbutterman New Member

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    virginia beach
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    1999 explorer xlt 4wd
    really wanting to see how this ended up. you said you would post more pictures soon and that was more than 3 months ago.
     
  6. QuietRiot25

    QuietRiot25 New Member

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    City, State:
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    98 Explorer
    is this thread dead? i neeeed to see this rig!
     
  7. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    HAAAH!!!!
    it was..til I did some CPR! (Im actually in iraq right now)
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
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    [​IMG]
    [​IMG]
    [​IMG]
    http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc3/20160_1215443987036_1256910079_30528276_3293703_n.jpg
    [​IMG]
    [​IMG]
    [​IMG]
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    [​IMG]
    New parts to come this year are a New winch, Exocage(help me with ideas)
    I have yet to install the weld on beadlocks, PSC hydro assist, and the solid front and rear diff covers, new seats, tach, cooling system, and lockrite front locker. It works really well as is, but I always want more. The rear may be redone with air shocks and a 4 link. I'd have to add a fuel cell if I did this though.
     
  8. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    [​IMG]
    [​IMG]
    same place as before, minus snow!
    [​IMG]
    ended up throwing a new trans in it in summer 2010
     
  9. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Lets see some ideas for a full exo cage!!
     
  10. BonesDT

    BonesDT Elite Explorer

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    Red '99 Sport SOHC 4x4
    @ 02-12-2010 02:32 am:
    @ 02-13-2010 01:56 pm:
    @ 02-15-2011 01:00 am:
    This was the fastest moving SAS thread I have ever seen!

    What kind of external steering box did you use?

    *edit - nevermind, I just realized QuietRot's post was 1 year later not 2 days later. Duh. Still, Trogg, you did a ton of work on that thing!
     
  11. rhauf

    rhauf Well-Known Member

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    91,93,98,&02 Exploders
    Exo-cage? now you've got my attention.
    (nice work on the SAS by the way)

    i exo'd mine, it looks a bit crude but i think i had some good concepts here, maybe there is something for you to gain from it. i have already put it wheels-up once and no damage whatsoever.

    video (this is most recent... taken last weekend)
    http://www.youtube.com/watch?v=ojffNSXLygM

    heres a pic
    [​IMG]

    build thread
    http://www.explorerforum.com/forums/showthread.php?t=293768&page=2

    i have finished a few details on the cage since that thread was updated (bars by the front fenders, and below the rear side window, and a cross brace through the rear, etc)

    do you have anything in mind so far for the exo?
     
  12. trogg

    trogg New Member

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    City, State:
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    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    Thank you for the compliments guys, the plan is to not deviate from the race look I've been shooting for, I would like to follow my body lines as much as possible, and plan on having my wheel well tubes rolled to match the cut, add a bunch of bracing, and tie in both sides under the hood and in front using the swing set already there. lol I am in Iraq currently but will be resuming surgery as soon as I get to my garage again!
    rhauf, How far off the body is your exo? whats your reason for putting it there, and do you like it there? I was going to try to stick mine rather close to the body.
     
  13. rhauf

    rhauf Well-Known Member

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    Did you look through the build thread? the pics there show pretty well how its all constructed (spacing from the body, etc)

    I tried to keep it about 1.5" from the body in most places (except around the wheel wells, where it flares out and is skinned inside to create street legal fenders) I didn't actually measure any spacing, just "that looks about right" and weld it.

    there are a couple reasons not to put it REALLY close to the body.

    the first of which (and my reason) is that when i roll it, no matter how much bracing i have on the cage (within reason), its going to have a little bit of flex, and i don't want it to flex into the body much.

    the other reason is that if the body is on its stock rubber body mounts, it will move relative to the frame (and relative to the exo-cage) and simple body mount flex will allow body/cage collisions. this of course can be avoided by fastning the body to the frame (and cage) firmly though.

    another consideration is that when you roll, the closer to the body the cage is, the more likely "tall spots" on the ground (such as rocks) will be to hit the body.

    of course, the closer it is to the body the better it will look.. theres no arguing with that.

    do you plan on doing any through-cab bracing?
     
  14. trogg

    trogg New Member

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    City, State:
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    1995 2 door SAS 37's 2"BL
    Thanks for the info!
    I plan on running a spare tire rack tie in with an X behind the back seat, and a hoop with harness bar behind the front, braced into the frame by the rear seat
     
  15. +RABBIT+

    +RABBIT+ New Member

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    94st
    hey man im new to the site i joined because im in the middle of my own sas ..... are you running stock sized springs and if so is that why you built your own spring buckets ... ive got the 78 bronco buckets and i was wondering if i should go ahead and buy the 5.5 springs or do as you did and go what looks like stock
     
  16. trogg

    trogg New Member

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    City, State:
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    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    id run what you have, then work your way from there... my year never came with coil springs
     
  17. gmanpaint

    gmanpaint It's Always Something! Staff Member Moderator Elite Explorer

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    How far back did the axle move with the leaf spring flip?

    I measured mine and there is a 5.5" difference from center pin to eyelets front to back. Did it move back 5.5" ??
     
  18. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    it moved right around 5 inches.
    Heres a few updated pictures
    [​IMG]
    [​IMG]
     
  19. alboy79

    alboy79 New Member

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    Year, Model & Trim Level:
    '98 sport
    This thread SUX!:salute:
     
  20. alboy79

    alboy79 New Member

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    Year, Model & Trim Level:
    '98 sport
    PS... what's your total wheelbase? The rear went back 5" how far forward did the front go? Please don't make me read it again.
     
  21. trogg

    trogg New Member

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    City, State:
    Kalamazoo MI
    Year, Model & Trim Level:
    1995 2 door SAS 37's 2"BL
    Ill measure it on saturday for you. unless you want to come out and wheel then have a bbq.
     

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