Something w/ rabbits. 72.5 pages of BS

So seeing as spring is just around the corner, I thought I'd start a thread on the future undertaking of swapping in the Dana 60.

The axle is from a 1986 "Fawwd" F-threee "fitty", sporting some kingpins and a whole lot of rust. I took this axle apart a few months ago (except stupid me didnt remove the pinion nut before breakdown ) and had it hot tanked. I wanted it sandblasted, but the machine shop owner smirked and said "naaah yo, that junx is too big for my blasting cabinet" .. okay except he didn't really say that cauz he's old and a really cool guy. ANyways *twirls blonde hair*, this is my plaannn:

- WMS-WMS this axle is just a bit over 69" wide so I'm going to cut the passenger's side down a few inches to match 'ye ol General Motors 14-bolt axle. So this is going to require custom axle shafts and I think I'm going to go Chromos and 35-spline outers off the bat from the most awesome guys at Complete Off Road.

- Drive flange or lockouts? They are about the same in price and its a dedicated trail rig so I'm leaning towards the drive flanges. Right now, the cheapest flanges I found are the Teraflexes at $180 for a pair. If anyone knows of a better deal, please let me know !!

- High-steer arms and a double-ended hydroponics goodness ("cylinder").

- Opposite-ended panhard bar! The idea is to mount the chassis end of the panhard on the passenger's side frame rail and the axle end on the driver's side. Doing so should allow a more simple and cleaner design since the axle-mount can be mounted on top of or near the differential housing, instead of a tower on the passenger's side (like in my current D44 setup). I also plan to boost the panhard as far up as possible to increase the roll center of the front suspension. Yeah the concept is a little strange but I'm hoping it'll work and won't have any issues (no drag-link to factor into the design). But if anyone knows of any problem running this config, please chime in!

*EDIT*
- Detoit Locker for the carrier. I'm please with how the Detroit in the 14-bolt has performed so I figured I'd run the same in the front. Of course 5.13s to match the 14-bolt.


So here's the little guy, he's been in this position for the past few months just collecting dust:

 

[91exploreron37]

What muffler setup are you planning to use? Dual in/Single out, Dual in/Dual out, turndowns etc.. and what type of muffler.

Headers look awesome btw. Will they fit on a stock bodied explorer.

 

[IZwack]

Looks good as always IZ, this gonna be done before you move out west?:

Thanks DB1. Unfortunately a recent event forces me to stay put for at least a few years so my dreams of the west are postponed. But I will be done with school by the middle of December '09 so after that hopefully the pace will pick up again and who knows, maybe one of these days I'll make a trek out for one of the Moab runs.

What muffler setup are you planning to use? Dual in/Single out, Dual in/Dual out, turndowns etc.. and what type of muffler...Will they [headers] fit on a stock bodied explorer.

The muffler will be a single-in, single-out for simplicity (after the catalytic converter). I dont really have any specifics as to what type/manufacturer, but I'm looking at the quiet ones. After the muffler, the exhaust will be "diffused" into the output of the radiator fan so there is no turn down or anything. Sorry the headers will probably not fit a stock bodied Explorer because of the way the driver's side goes over the bellhousing.

 

[dkchrist]

Hey IZ, I could use a set of headers Looks awesome!!

 

[IZwack]

THanks DK.

Been working on the headers for the past week or so after work/class.

 

[FROADER]

A
w
e
s
o
m
e
!

 

[JTX]

Looks good, keep up the good work. Any sound clips with open headers?

 

[techieman33]

I wish I could get some long tubes like that.

 

[IZwack]

Last week was the last week of school forever (and ever) so its about time to get back on this thing.

I ended up going with a pair of V-band clamp thingies because there's not enough room to snake the passenger's side header between the cage tubes and the transmission with regular exhaust flanges.

weled the v-band clamp rings on:

Shortened the catalytic converter ends and welded on a pair of exhaust flanges:

 

[gmanpaint]

Simply amazing.

 

[jwrezz]

I actually like those clamps. Neater installation, and instead of sealing w/ a gasket and 3 bolts, it's sealed all the way around. This will be very cool once all done!

 

[MrQ]

Simply six sick silver snakes snarled. LOL say that 3 times fast. : Looks good, man. Hoping for some audio soon!!

 

[IZwack]

Thanks!

I actually like those clamps. Neater installation, and instead of sealing w/ a gasket and 3 bolts, it's sealed all the way around.

Agree but they're kind of expensive -- $25 to $30 each plus shipping.

 

[black91EB]

Shortened the catalytic converter ends and welded on a pair of exhaust flanges:

Man, I gotta get a better welder, that's beautiful.

 

[jwrezz]

Man, I gotta get a better welder, that's beautiful.

Get a better welder, or become a better welder? Kidding, but I know, some times skill can only get you so far, then you need to spend the $$!

 

[black91EB]

Get a better welder, or become a better welder? Kidding, but I know, some times skill can only get you so far, then you need to spend the $$!

Yeah, I've got a harbor freight 110V 55A stick welder and a Lincoln Weld-Pak 80A Flux core. Both do good work, but nothing nearly as pretty as this.

 

[jwrezz]

Ah, good old harbor freight. I must've gone thru 3 torque wrenches from them, but for $15, you can't go wrong! ONce I hit 10, then I'll be wishing I had just spent the $150 on a good digital one tho!

 

[section525]

I wonder if IZ has been working on this.

 

[IZwack]

Nope, been improving the van. I'll get back to this after New Years.

 

[Rick]

Dude, I hope you win some kind of award for this.

A set of "major awards" for Iz!!

 

[Paul]

A set of "major awards" for Iz!!

Ohhhh, it's beautiful, it's a work of art..."

And the welds look great, too. . .

Paul
'91 Sport

P.S. "You'll shoot our eye out!"