Crawlin91's build thread

[whitetrashfab]

Nice build! I like my Duffy doubler but the dana 60's have proven to be stronger then my T case... and driveshaft...

http://www.explorerforum.com/forums/showthread.php?t=304600&page=2

As for driveshafts, get a van (96 e350) dana 60 pinion flange for your font axle and a stock explorer sport rear driveshaft will bolt up (mine did but my axle is pushed ahead a little). You also need to swap a rear T case output flange to the front output shaft (get rid of the CV pos). So far the front has held up fine... not so much for the rear

 

[crawlin91]

Ill look into that for the driveshaft, my dana 60 will be pushed forward but I am not yet sure how much, should have it back on its own weight soon and I can take measuremnts.

I finally got some wheels and tires now too.
H1 grooved 37" Military take off tires and recentered 8 bolt beadlocks. I started cleaning them up for paint and took a few pictures.

 

[crawlin91]

Wish I had access to a blasting cabinet and a paint gun, sure would speed the process up, takes a bit of work to go from start to finish on the wheels, the shipping company lost my o-rings and valve stems so i am waiting on those.

 

[crazyflights]

Man its Looking good!!!

 

[crawlin91]

Put a boot on the doubler shifters, not fancy but it will keep out the heat and the noise.

finished the wheels up and got them assembled and aired up

I went with lightweight pvc inserts over the magnesium or rubber runflats that are used on the Humvees but the tire and wheel combo is still quite a bit heavier than my old 33"s on black steelies.

Then I focused on getting the rear axle ready to install, my plan is to have the SAS done by next weekend and roll it in the garage to do the rear axle and body work.
Axle primed

Shaved diff cover to match housing.

Laid down some paint

new ruffstuff 14B disc brackets

still need to install studs and brake parts

Ordered a set of these from up north...:icon_cheers:

- Geometry adjusted for steering and kingpin Axis Inclination Angle - Resulting in a perfectly paralell surface between arms.

1.5" Thick at the knuckle mounting surface.

- 100% CNC'd from Billet Steel.

 

[Slowlyvverot]

too cool

 

[HAPHAZRD04]

Nice build!

 

[crawlin91]

started boxing in the frame, ran a new crossmember/spring hanger .250" DOM, and did some plating

Well, she sits a little wider now.

I will have more to update tomorrow, and this weekend!

 

[mynameisaric]

lookin good!

 

[crawlin91]

Thanks. I need to move the shackle hangers a little and finish up with the steering and brakes.

 

[RockRanger]

What did you use to make the shift boot?

 

[crawlin91]

What did you use to make the shift boot?

I used heavy rubber/vinyl type material, reminds me of a mouse pad but thicker. Just cut two slits long enough to throw the shifters and tucked the material back underneath the cab padding and carpet.

Redid bearings and seals, in the 14 bolt. Installed GM rotors and calipers and pounded in new studs.

I had to cut my mid cab mounts off to fit the shackle hangers to the frame and will need to fab new ones. Tomorrow the cab comes off completely and I can finish welding and boxing the frame.

 

[crawlin91]

 

[rkbonds1]

Sweet looking build!

 

[crawlin91]

I cut about a foot off the frame...Should be able to get the rear axle in tomorrow.

 

[crawlin91]

I cut another 4-5 inches off the back and burned in the new rear crossmember. I also mocked up/tacked in the 14 bolt, I need to change the shackle angle just a bit and I can finish welding it in. Here are a few pics...

 

[crawlin91]

Its a roller...well almost. The rear should settle after I reset the shackle angle and get some weight back on it but it is getting closer!

 

[mynameisaric]

 

[j_mazala]

Looks nice. Where did your wheelbase wind up at?

 

[crawlin91]

Looks nice. Where did your wheelbase wind up at?

Thanks. I ended up at right at a 115" wheelbase.



Well, I finally bobbed the bed, took out about 1.5 feet, to match the new w.b. I cut the bed with a sawzall (high tpi blades) and 4.5" cut-off wheels. Cleaned everything up tacked it back together slowly, to keep warping at a minimum, then hit it with some body filler, I used Evercoat, Rage-Extreme, I'd recommend it to anyone. It was fairly easy to sand and set up quickly.

I applied three light coats of filler sanding with 80 grit in between and 100 and 220 to finish, the end result came out very smooth. The bed has other scratches and a few small dents that I did not bother taking care of. Its a wheeler, and if I destroy this box I can make a flatbed for it. Mostly, I just wanted to try my hand at working some sheetmetal. I still need to prime and paint but here are a few teasers

After the first coat of filler and sanding...

Last coat before any sanding. Sorry for the cell phone pics, I really need to get out the camera to show off the end result.

One with the bed sitting back in its place.