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  1. 1

    Project Green Hornet '01 Sport SAS

    So this project has come to a little bit of a crawl because of this shaking issue. I'm thinking it's because of the balance shaft in the 4wd engines for the time being because I have no other idea what it could be. I'm thinking about adding the balance shaft with a timing chain update but my...
  2. 1

    Project Green Hornet '01 Sport SAS

    As a matter of fact I do. How are you familiar with ATC?
  3. 1

    Project Green Hornet '01 Sport SAS

    I got them from Amazon. They are the laser blue rocker switches. They had several different images for whatever you wanted them for. I also bought a Rugged Ridge Rocker Switch Mount which is a 4 piece modular setup so you can mount your switches to a piece of stainless or whatever you want to...
  4. 1

    Project Green Hornet '01 Sport SAS

    Not too many. I got the transmission shifting worked out. I decided one day to just throw in another quart or two and see what happened since I added the drain plug it wouldn't be hard to take it out if need be, which it didn't. So that was good. After that I took it around the block, or...
  5. 1

    Project Green Hornet '01 Sport SAS

    I've been able to get some work done the last few weekends. Here is the final plumbing of the fuel cell. Here are the shift knobs and levers. Underneath looking at the links. Today was a little bitter-sweet. I topped off all the fluids in the transmission and...
  6. 1

    Project Green Hornet '01 Sport SAS

    Not yet. I'm still putting it back together after putting in the transfer cases and stuff. I would think that they would be better than the OZs though because it doesn't have the center strip running around the center of the tire, but I don't know that for sure. I'll be sure and report back when...
  7. 1

    explorer sport pics

    Amazon claims they are the same size for the front and rear. Is that true?
  8. 1

    Project Green Hornet '01 Sport SAS

    Thanks. The inner fenders were pretty easy. I think it was mostly just plastic clips that I had to take out for it to come out. I hung on to them for a while in case I decided to put them back, but it is a lot easier to change spark plugs and access other areas of the engine bay so I chucked them.
  9. 1

    Project Green Hornet '01 Sport SAS

    I got to work a little bit on the cross member the past few days. It's not finished yet, but here is a sneak peak: There is still a lot of cleaning up to do. I am also going to cut out a skid plate for the bottom of the cross member.
  10. 1

    2003 Sport Trac - SAS, SOA started and here's a sneek peek.

    To me, cutting out that cross member was probably the worst part of the whole project. I also only used a 4-1/2" grinder and sawsall and doing that upside down at times was not fun. Looks good so far.
  11. 1

    Project Green Hornet '01 Sport SAS

    Well, I got the transmission tore down and put back together last weekend. I wanted to rebuild the clutches and stuff while I was in there, but the main reason was to get to this guy: I swapped it out with a 4x4 output shaft and swapped the tail housings. I also installed the remaining...
  12. 1

    Project Green Hornet '01 Sport SAS

    I got to work on removing the transmission this weekend. Really didn't have any problems. The toughest part was getting to the very top bolt of the bell housing without making a mess. What I did since I already had the center console removed was take that cover off and cut through the...
  13. 1

    2005 Ranger build D60's, V10 swap, doublers, shenanigans

    I'm excited for this one. :popcorn:
  14. 1

    Project Green Hornet '01 Sport SAS

    Well, as work started getting busier and the small issues of mating the transfer cases kept popping up, I decided to just go ahead and buy the rest of the BehemothDrivetrain Strongbox since I already had the intermediate shaft. It took a little longer than expected to receive, but Jacob was...
  15. 1

    Project Green Hornet '01 Sport SAS

    I got the inserts mounted and took it to work to machine the surface flat again. Here are a couple progress pictures: Work has been really busy, so progress is slow, but steady. I still have to machine the main plate, then make the adapter plate for the 205.
  16. 1

    explorer sport pics

    I disagree. As long as you don't cut something stupid, cutting may be necessary. Before cut: After cut:
  17. 1

    Project Green Hornet '01 Sport SAS

    Here are a few progress pictures. I machined the block meant to fill the hole made for the shift rail. It took a little massaging, but it turned out pretty well. My plan is to mount it, then machine the extra flat for a flush surface. My initial plan is to use a chemical...
  18. 1

    Project Green Hornet '01 Sport SAS

    Got started on cutting up the 1350 case today and got a first hand look at what its going to take to make these 2 cases play nice with each other. I had to make a notch for the shift rail which is in the low position which is all the way out: I cleaned up the edges with a dremel to make...
  19. 1

    Project Green Hornet '01 Sport SAS

    Here are some snap shots of what I have in mind for my design.
  20. 1

    Project Green Hornet '01 Sport SAS

    Well, it took a little longer than I expected to get my intermediate shaft, but it is finally here and it looks pretty good. The guy I bought the NP205 from told me that it was twin sticked. It turns out what he meant was he cut the shift connector off and had 2 rails. Anyway, I ordered a...
  21. 1

    Off-road 2001 Sport build

    Offtrac is right on track (no pun intended). There is way too much information that has already been covered. There have been several people who have done everything from a TT to SAS with tons of pictures. If you are planning to keep the 2WD, I would just do a TT with warrior shackles in...
  22. 1

    Project Green Hornet '01 Sport SAS

    Here is a little teaser update: These are going to be joined by a shaft I bought from Behemothdrivetrain.com. It should be here in about 2 weeks and then I can get going on cutting and fabricating the joining plates.
  23. 1

    Project Green Hornet '01 Sport SAS

    Yea I've still got the factory 4.10's right now. I keep bouncing back and forth about a 302 swap or the supercharger. The supercharger seems easier with the computer system etc. but I used to have a '92 f150 with the 302 and loved it, so that part of the build is still up for discussion.
  24. 1

    Project Green Hornet '01 Sport SAS

    I haven't really gotten much done on this lately. I drive it to work from time to time and the 37's feel good. I plan on regearing to something like 4.88 or 5.13 which would help I think. I still have more planned like a doubler and possibly a banchee supercharger kit. But that all has to wait...
  25. 1

    01 STrunner's Sport Trac

    How easy/hard is it going to be to remove the transmission/t-case with your crossmember welded to the frame?
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