Completed Project Turboexplorer's Full Width SAS Build Thread

[turboexplorer]

.... but this is a great thread for those that will learn from your work here.

After it is finished, and taken to the trails, you will see what needs to be tweaked, and can make some final comments on what works, and why.

How many hours do you think you have in this build? :scratch:

I hope the thread will help others. I have posted a pretty good step by step build for this truck I think. Now that the 1st and 2nd gens are very cheap for a decent one, more people look like they can spend more on making the rig than buying it.

Yup I am sure I will find several things that could be tweaked some to make it better or smoother. I really hope to have it rolling by the end of next week, but that all depends on what time I am able to put into it.

I personally have about 220-250 hrs or so into the build. I had a few of my friends that helped as well and they both have probably about 40-50 hrs in it as well.

 

[turboexplorer]

Here is the steering stabilizer that I will be using. It will mount to the axle on top of the trac bar mount and then I have a clamp ring that will clamp to the tie rod and then have tabs welded to it so that it can hold the other side of the stabilizer. This way it can be loosened so that you can spin the tie rod to set the toe.

It is a FOX 2" emulsion shock for the rear of a J*** TJ. So I am using a rear j*** shock for the steering stabilizer for mine. Anyways almost all of the Nitrogen has been bled off and the shock was fully revalved super stiff. Scott at Dirt Fab did all that for me. This will allow me to adjust it if ever needed, rebuild able, and gives me more than enough throw for the steering swing.

 

[turboexplorer]

Here is the rear driveshaft for the rig. This thing is a MONSTER!!!!!!!! I did go with the CV style shaft. It should be smoother and run longer than a traditional single U joint shaft. Smooth and longevity are what I really want. Also this shaft is all 1350 parts This stuff is more or less diesel 1 ton stuff Again major overkill but unless I set the whole weight of the truck on the shaft itself this thing will never break!!!!

This shaft is 100% new parts! It was built by Curtis at Tattons Drivelines in Salt Lake city. This guy is amazing and super easy to work with also does it at a great price to. I paid $400 for this whole shaft with everything new painted balanced shipped to my door.

Curtis Tatton
West Valley City, Utah
Phone: (801) 685-0056

I have a picture somewhere on my phone with it next to a pop can and the pop can laid on its side is only has tall as half of the U joints. This thing is huge! Very very happy with it and the service and speed! If anyone gives him a call tell him Kyle with the CV explorer shaft sent you.

 

[turboexplorer]

Front and rear of the truck at full droop. Just before I set the full weight of the rig down. (P.S. I built the trac bar after I did this and the axle was taken off the supports)

See no trac bar. The triangulated upper links held the truck in place just fine without the trac bar.

 

[turboexplorer]

And some more this time when the trac bar is done and installed as you can see.

 

[turboexplorer]

This is the ride height of the rig!!! I am SO happy I did all the research and spent the time and money to do this build right and professional. All the math and (guesses on corner weight) where dead on. When in full droop the springs still have tension on them from the adjusting rings and then when you set the weight of the rig on it the ride height is perfect!!!!!!!!!!! The springs should settle about a 1/2" or so in the front which will put the front a 1/2" lower than the rear measured from the top of the tire to the highest part of the curve of the fenders. Perfect. Also on a good note the weight was put on the shock hoops with no cross brace and neither one even budged at all!!!

 

[turboexplorer]

And for some more pictures of it at full droop. These are when I had to lift it and the instructors went over it with a fine tooth comb in order to see what I should get for a grade in the class and to judge the quality of the work. The tall screw jack in the front is just for support since the rig now has the radius arms in the way the lift pads are far enough back that it was fairly nose heavy so I stuck it there for some piece of mind for me. But yup here it is all done and ready to roll out the door. (Rear shocks, sway bar, finished steering components, etc aren't on yet, just wanted all the fab stuff done I could put all that on at home)

Me standing next to my rig. Gives better perspective to how big the truck is

 

[turboexplorer]

 

[turboexplorer]

 

[turboexplorer]

Rolling it out of the shop!!!!! The pictures everyone has been waiting to see.

And here it is sitting in front of my 04' Taurus! When you sit in the Taurus all you see is the Ford emblem. But When I sat in the truck I did notice that I will have to be careful backing up and things because it is very tall and will be hard to see things that are even remotely close to the back of the truck. A good walk around before you drive away will be necessary.

 

[turboexplorer]

And here are the pictures of it after we put it up on the trailer. My Dad pulled it with his 03' King Ranch F-150.

 

[cmhaah06]

I dont even know what to say. Great quality build. You my friend have some mad crazy skills. AHMMMMM FAB SHOP COUGH COUGH..... Sorry. Anyways. Nice rig you ended up with there. From my point of view looks like you earned at least an "A".

 

[N2FORD]

That is awesome, it looks really good and the quality of work you have put in is great. I have a D44 out of a 76 Bronco to put in my Mounty if you want another project. Very good thread and thanks for all the pictures!!

 

[brnbomr]

great build. i have been following this for a while. looks very well thought out and done correctly.


so whats next for it?

 

[turboexplorer]

AHMMMMM FAB SHOP COUGH COUGH..... Sorry. Anyways. Nice rig you ended up with there. From my point of view looks like you earned at least an "A".

I wish! That would be a fantastic job but I don't have any capital to start anything yet. I plan to do at least side work and work my way into my own equipment.

And yes I got a 100% in the class I do really well in the grade side of things as well and then the shop side of the grade you can see in the pictures.

so whats next for it?

Get it drivable mainly. All the rear has left is the brake lines. The front I have to weld the steering box plate fully on, then make an intermediate shaft, then run the power steering lines, then front brake lines, then align it. Then I should be able to drive it.

After that I will have to load the front gears have the front driveshaft made and then I can wheel it

 

[mounty71]

Any plans to build one of those 8.8 skid plates still?

 

[GRNMACHINE]

Cant wait to see a vid of you driving this Monster. Probably my favorite build to date. Incredible job!!! That is One Awesome Stance it has. I am sure your side work will be steady!!!! Late sorry to hear about your place when you got there, that was pretty shady. Wish I was closer to ya, would love to drop off my Ex!!

 

[turboexplorer]

Yep the move hasn't been what we where hoping for. The apartment thing and now my job is frustrating. No work and being on flat rate it kills my income. So frustrated that Ford said they where very busy and today I spent 4 hrs standing with no work to do.

Anyways enough with my woes.

Alright to catch up with what I did last week on the truck.
So here are some pictures with the rear shocks on the truck as well as the rear sway bar. The shocks are bilsteins 5100 series.

 

[turboexplorer]

More.

 

[turboexplorer]

Painted my front cross member.

Painted my tie rod, my drag link, and all 4 steering joints, jam nuts, castle nuts.