1956 F100 Explorer Chassis Swap | Page 15 | Ford Explorer Forums - Serious Explorations

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1956 F100 Explorer Chassis Swap

Progress

Nice work! It is cool to see it coming back together.
Put an oil filter on that thing to keep dust and dirt out.
That race car in the bottom picture looks a little front heavy. lol
I am sure that you are a super hero to your son, you better get a cape if you don't have one already.
 



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Ha! Thanks 4pointslow! Sometimes I wear a Snuggie for laughs..... does that count? They are incredibly comfortable though, lol.

I still need to thoroughly clean the oil/coolant adapter piece before officially installing the oil filter. However, I had (and have still now) covered the hole, just fell off while moving around. Definitely temporary.

Been working upwards of 60 hours a week and it's been tough to get out there lately. I'm sure I'll have more time just as it gets too cold once again. :banghead:
 






I forgot to mention a while back that I tried out the welding clamps, I mentioned buying them, but this is what it's like while using them. I haven't done any welding with them yet, but here they are in action anyway.

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I still have so many parts left, does anyone need any of these parts? I'd take them to the scrapyard, but I sold the F250 and the trailer is gone. 20 mins West of Little Rock, AR.

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Public service message.... careful with car ramps:

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And don't forget to keep a bottle of this stuff this winter season:

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Sitting here looking back at previous pages, I thought it would be cool to look at some highlights over the last year since I started. I feel like I could have done more, of course, but not too bad for what else I had going on at the same time.

Day 1 when I loaded it up onto a trailer:

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Oh, how many times I came to potential disasters by doing 99% of this by myself:

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But then having what I'll call today "help"

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Weather and temperature struggles:

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Excitement about not completely being wrong about measurements thanks to measuring 100 times and cutting many many times:

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Playing with new tools, toys, and making greasy and rusty things "new" again:

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Turning this....

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Into something like this.....

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Instead of this, lol

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I believe I'm at the halfway point in the build. Not sure how much time I've spent total on this project, but I know it's been a great feeling accomplishing this much so far. It's the experience and learning I have received that make it worth it and the advice and compliments I've received from all of you from this site that help drive me forward with it. This thread has been viewed well-over 50,000 times so far and amazes me during research on the web how many times I see my own photos on Google searches. Just when I think I have found someone else posting a similar story I want to look at, it's hilarious when I find that it's my own. :)
 






Some exciting news since my last post.... I have been in contact with Dave who built the blue 56 from page 1 of this thread.

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He's been kind enough to tell me more about his similar build, pictures that have never before been seen on the web, and details that have regained my confidence in how I will proceed moving forward. I'll share some of that soon (pics too, if permitted).

He did tell me that he has no regrets using an Explorer for the donor. His build was completed about 7+ years ago and it's still going strong!!! He did retain the 56 dash, but used the Explorer steering column and some controls. The one thing that he said that rang most-true to how I feel with the current phase in my build was, "bottom line is, in every design, each decision you commit to becomes a constraint to the next choice."

I'm aiming at getting the engine compartment (somewhat) back together as my next steps. From there, I need to go back to the cab for more "treatment."
 






Taking advantage of the mild weather we had over the last couple of days, I did get to work some in the shop, I did, however, have to keep an eye on my boy, so....

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... he was occupied, lol.

Due to the pictures that Dave sent me, I realized how much of the front end would be able to be retained. Having the Explorer sub-frame helps reduce the amount of custom fabrication needed for things like radiator mounting, A/C, cooling lines, wire routing, and more in a factory "methodology". Additionally, having the correct alignment for the fan reduces the need to purchase an electric fan or otherwise chance really tearing up stuff if I'm off by any of my own measurements.

You can see Dave's Explorer hiding in there. This should fit just fine considering the frame ends on mine butt up against the 56's front. The Explorer front end will be held upright with stability and give additional structural support during (hopefully never) any collision as it uses the original frame mounting points.

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More will be trimmed, but you can see the sides are gone. Although I'll need to relocate the airbag sensors, the entire cooling will able to left as-is with little to no modification as everything between the frame rails will fit within the opening of the 56's "hole."

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You can see by the pic below, the radiator on this truck is not bolted in place, no fan shroud, could get dangerous.

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I trimmed off the front of the cab to increase clearance, reduce work needed to fill most of the 93 holes (yeah, I counted) and cringed while hacking into irreversible areas for mounting the computer.

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It lined up well, and the wires are not being tugged like the example I posted about on page two of this thread.

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I purchased a set of Fel-Pro exhaust manifold gaskets for $7.99 at AutoZone and mounted those puppies. A lesson learned - go ahead and install these things BEFORE mounting the A/C compressor and power steering pump. The bolt in the very front is BARELY reachable with midget fingers and a 1/4" drive socket/extension due to the lack of space. Nearly two hours to complete. Grrrrrr. You can see more things being attached and going back together here.

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This side view looks a bit messy, but it's not too bad in person. Once the fender wells are in place with some structure, this stuff will neatly mount in place.

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Not sure if it will all fit yet, but I'll try to retain the intake with filter to keep the sensors and routing hardware.

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It's amazing to think what's under the cover of that finished truck :D Nothing out of the ordinary until you open the hood :D

Very cool!!
 






Truck

This thing is going to be awesome!
I cant wait to see what the dash is going to look like too!
 






I'll have to get used to people asking to see under the hood (for proof) once they climb inside and see an Explorer dash and wonder how it got there! It may not look like it now, but there are "in-person" moments and views of this thing that just blend together like it was designed to fit this way and I've already thought about how much easier it will be for me to do the next one!

A quick look into the past again, you'll see a sneak peek at the dash:

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I can't wait to get it all together!
 






Hey buddy!

Even though I haven't posted in a while I am still sitting back and enjoying seeing this rig come life. Keep up the good work!
 












Hell yeah man !!! Now this is a "Hybrid", a good kind too, not that sissy Prius mess. LOL
 






I want to do the same swap with a 1978 / 1979 bronco or f-series truck. Doing research on how much work it will take.
 






Hey buddy!

Even though I haven't posted in a while I am still sitting back and enjoying seeing this rig come life. Keep up the good work!

Thanks! It may still take some (lots of) time, but I feel like it's taking shape.
 












Hell yeah man !!! Now this is a "Hybrid", a good kind too, not that sissy Prius mess. LOL

LOL! AND I'm adding more cubic inches than original! No Prius here! :thumbdwn:
 






I want to do the same swap with a 1978 / 1979 bronco or f-series truck. Doing research on how much work it will take.

Ewwww..... that would be awesome! I was born in 78 and a Bronco from that year is in my radar for a future project. I wouldn't think that an Explorer would be suited for a Bronco build unless you were just going with drivetrain only. Reasons I say this; width, height, wheelbase, etc. If you do this, please keep me posted with your progress! :salute:

What you might need is THIS frame:

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Happy New Year everyone. It's time for some catch up.

A bit has changed since my last post. Today I woke up excited that I had no plans to do anything and what else might I do? Yeah, work on the 56!!!

I recently got new parts using a gift card for AutoZone that I got for Christmas. I now have new Motorcraft sparkplugs, serpentine belt, oil filter, and lower radiator hose. I got a quart of POR-15 paint and a tube of POR Patch that came in the mail today too.

So, I set out to the shop to warm it up, organize, and then it happened. The smell of a dead rodent appeared. I saw some droppings by some tools a couple weeks back and set out some D-CON mouse pellets, so I knew that I got it, but where could it be? I couldn't find it anywhere until I was organizing the shelf that I have been storing all of the disassembled Explorer parts and restored 56 parts. A huge box I had been using was oddly disfigured and my heart sank.

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Whatever had been living here has been $#itting, pi$$ing, and eating on any non-metal thing in this area. I found the rotting carcas inside the box still and I couldn't help but freak out thinking that perhaps there were more ready to jump out at me when I moved anything else. Still not sure exactly what it is, besides dead. It's as big as a rat.

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Most of the damage was to plastic bags, boxes, and the sun visors. I guess I may use this as an excuse to find some 56 visors. And I was getting all excited to have lighted mirrors, lol.

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I had a hand from a neighbor, that needed my engine crane, which helped make space in the cramped shop, where I could move the front clip back up front for more fitting/trimming. You can see that I cut the top corners off the radiator support panel. I'm sure I'll have to trim more for the hood to close, but for now this works for visualization.

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I noticed before that there would be some rake in the stance, but on the level shop floor I could see how severe it was. I really needed to bring it up a bit, but without risking height for the dash without need for filler, like I've seen a couple times. I personally don't like filler.

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I had to modify the cab some more to stabilize the angle, the only place I could do this is at the rear. The problem with this is that the rear sat flush down on the floor of the Explorer. I needed to loosen up the front, push the whole cab back, and then tuck the rear under the floor. This also required trimming the corners that wrap around the frame. It was lowered about an inch. This seemed to do the trick. If I can close the hood, then we're fine. Sorry, I didn't get any good pics of this but you'll see some in the background in later pics.

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With the adjustments, the front clearance is still a mere 7". I guess that's still higher than my car, perhaps this will be just fine. (Insert "that's what she said" joke here) :eek:

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Since I had the cab in "semi-permanent" position (for the millionth time), I screwed the cab in place to keep it from shifting prior to welding. I decided that it would be time to remove most of the steel braces I had inside the cab. I left the passenger side intact due to additional work still needed on that side.

While I was cleaning off the shelves, I decided to see how well the center console fit. Would it allow me to open the cup holders? No, but I can see myself using the extra vents in the back of it to my advantage. Did you know that there are actually heating elements inside the ducts for the rear passengers? Interesting tidbit. Why don't all cars have this for ALL the vents? Hmmmm.....

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Then I decided to inspect the seats for rodent damage. All was fine, but while I'm at it, how does it look inside the truck???? My heart was racing as I climbed into the loose seat. Without a battery to power the seat (nor wiring) I couldn't put the seat in a natural position, however, I was super excited to have that moment. I couldn't tell if I was shaking due to pure excitement or if it was just simply cold.

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Now, in other news...

Before Christmas, I came across a boat for sale for $400. I wanted to ask, "what dark alley do you want me to meet you in?" as it seemed too good to be true. Once again, not only was it real, the gentleman just renewed the tags and registration for the boat in October. This thing has bedS (plural), a bathroom, kitchenette.......

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Sound system, refrigerator, nearly flawless interior.......

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Long Range CB radio, CD player, fully enclosed top with bimini top as well.....

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Although the outside seats are weathered, they should be easy to recover and it needs a good cleaning. The main thing wrong with it is that the outboard has a crack in the bearing cover. I actually found an entire lower unit shipped to me for $129, so that will take care of this.

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I used an Expedition to drag it home. It dwarfed the Expedition to the point that it looked like a PT cruiser. It is huge and heavy. To give a an idea how big, this one below is identical (a year older though) in size but with the full top in place.

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I also found a local Craigslist ad with a 5.0 installation. It looks like newer F-150 interior components.

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I'll be back again soon with more updates on the build. Thanks for viewing!
 









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When you are working on any project, some of the most-detailed work sometimes goes unnoticed by others. But only you know what you did to get that piece to fit exactly the way you want it to. The big pieces are usually the most dramatic, so I am excited tonight to show off what little I've done that makes such a big change. By installing the largest single piece of a truck (aside from maybe the cab), the hood, what a difference it makes! So, ladies and gentlemen, without further ado, will you please give a warm welcome to the most complete front end this truck has seen since the inception of the project.....

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In order to get the hood to close, I needed to remove the hood support bars that run from front to back. They were resting on the Explorer's radiator support and would have required more cutting than I had trimmed. In fact, it would have taken cutting some supports for the radiator and modification to the air conditioning lines, so they had to go. I will need to move these brackets outwards 3-4 inches to avoid these consequences. Perhaps the hood doesn't need them, but I wouldn't think they were built this way unless they did something, like control flexing, especially when it's hot.

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Since I was man-handling the hood to get it into place, it was impossible to get pictures easily. (especially with my broken phone shutting off randomly when in camera mode) I'll have to get more pics later when the hood hinges are bolted better and can hold hood for the photo opportunity. I actually used the same bicycle pulleys to help maneuver the hood into position, it made it possible to do this by myself. Yes, it was a bit scary knowing that one slip while flipping the hood over could have ended the hood's life.... or worse.

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To complete the look, I temporarily added the grill to further the affect. I am like a kid in a candy store. I'm more than a little excited about this tonight!!!

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