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Dannyboy's Re-Registry

What better time than now to do this.

Here is my old 94
http://www.explorerforum.com/forums/showthread.php?t=100935

Just when my transmission crapped out again, I saw my current 91 for sale on this forum. Joe (Lilmule) owned the truck since new and moved to Milwaukee. When I got this truck I had no clue what I was getting myself into. Honestly, I purchased the truck for the glass fenders and C4/C5 transmission setup. I didn't want to deal with TTB, didn't know who "Autofab" was and didn't like that it was spring under and had some 9" axle that I knew nothing about. Here was the plan, combine these 2 trucks, solid axles, updated glass, C4/C5 tranny, 37" swampers, and ditch the blue truck.

91Explorer1012Medium.jpg




Luckily for me and this truck, I didn't have time to start parting it down. I took it out on a few rides, fully rusted out and couldn't believe the "shalackin" I could put into this truck. I spoke with Joe on the phone a few times over the first year and he kept going on about how great this setup is but never really knocked my solid axle idea or told me what to do. I did start to see that some serious money was spent on this rig the first time it was built.

When Joe mentioned his bill was in the 5 digit numbers at various places like Autofab, Currie/Mogi etc, I realized that I needed to do some more digging into what I had gotten myself into.

Disappointed my 94 that had nearly $30,000 into over the years was sitting dead with transmission parts in a box in the backseat, I researched what I had. I realized that the blue 91 was the truck to move forward with, XL over a Limited means less issues, power features to short out and it had some serious potential. I parted down my 94 and laid it to rest.

junkyardtow.jpg




The for sale ad even said "Needs TLC, after that..."

and this brings me up to speed.

I ran this truck for a while, my avatar photo was taken without spending $1 on this truck, I couldn't belive taking a truck that was sitting could handle this abuse. This little thing was just a machine.

DSC01836.jpg


Then I went to Truckhaven and it was pointed out by other members that I had some work to do, a shackle was nearly rusted through, radius arm bushings were toast, etc. I didn't care, I have a trailer and a tow rig...this trip it paid to have them. I was running a wash and snapped the passenger side u bolts, puncturing the tire and leaving the truck not driveable. I don't even think a trail repair would have gotten me to drive this out.

truckhaven046Medium.jpg


I still got a good weekend of wheeling out of this truck and still had the attitude that I could leave it behind if something happened to it for how cheap I bought it.

Still considering the Dana 44 I have sitting at my house, I decided that I didn't want to give up the speed. I visited Autofab while in San Diego and John was a very cool guy for discussing a truck he built probably over ten years ago. It was at that point I decided to go forward with the original intention.

One trip to Truckhaven with some new updates such as 33x12.50s instead of 33x9.50s, new spring pack to replace the original 11 leaf spring under pack (which raised the rear of the truck nearly 5" from the tired pack), new brakes, auxilay fuse panel, the bumper from my 94 got me excited making it look like a whole new truck.

DSC_0537_resize.jpg


It was at this point I got bit bad by the bug. I needed new shocks, the rear was just too bouncy, I was going fast and am madly in love with the lady who loves to ride shotgun so now 2 lives needed to be protected and lots of stuff needed to be fixed to keep up with this speed.

Well, 6 months in the fab shop, the truck has just had it's first run with the "new" setup.
IMGA0088.jpg


So here is the breakdown

Engine
Ford 4.0
KKM filter
stainless intake
hypertech chip
headers
exhaust

Transmission
C5 3 speed built by Mogi Enterprises with all C4 internals
reverse valve bodied (an auto but you need to manually shift)
Art Carr shifter
B&M tranny pan
91009.jpg



Transfer Case
Stock pushbutton transfer case (button in a not-so-stock dash)
spaced back since C5 tranny is much shorter than stock, retaining stock front driveline length

Front End
Dana 35 TTB, AutoFab kit (the $3600 kit before shocks!!!) inlcudes extended radius arms, tranny crossmember, triple shock mount (1 behind, 2 in front) currently running Rancho 5000s but 3 of them keep it in control
16" of wheel travel approx 6" of raised height over stock
4.56 gears-no locker (don't want one)
warn manual hubs
5/8" wheel studs
limiting straps
"Winter" mods on inner axle shaft and passage

IMG_6834.jpg

IMG_6836.jpg


Rear End
Ford 9" built by Currie, fully trussed
4.56 gears w/ Detroit quick lock
Disc brakes, Wilwood 4 piston calipers, 2 piece rotors (see writeup)
5/8" wheel studs
Valley Spring Service 11 leaf spring under leaf pack
Total Chaos low profile u-bolt retention plates
King 3.0 16" travel triple bypass piggyback shocks
Aftermarket Shackles
Wilwood brake proportioning valve

IMGA0089.jpg

IMGA0091.jpg


Wheels/tires
I've ran several setups, currently running 35" BFG Krawlers on 15x10 steel wheels.

Other Exterior
Perry's 2000 conversion front end, 6" pull fiberglass
4 pin removable fiberglass hood
autofab prerunner front bumper
Dannyboy's designed rear bumper/2" receiver
Rock sliders
2-8" 130 watt driving lights
4 rocklights mounted 2' behind each wheel
DSC_0538_resize.jpg

DSC_0813.jpg

IMGA0092.jpg


Cage

HUNTER OFFROAD custom built roll cage-www.hunteroffroad.com
*all interior gutted for tight fit
*in-cargo shock mount for King shocks
*4 bucket seats incorporated and tied into cage
*ties into frame in 6 positions
*ties into body in 16 positions
*spreader bars
*A-pillar support (required windshield removal)
*1.75" steel and 1.5" (approx 130 feet total)
*Hi-lift Jack mounts, spare front/rear driveshafts, shovel, fire extinguisher mounts
Picture008medium.jpg

fd_001_Medium_.jpg

IMG_6839.jpg

IMG_6842.jpg



Other work by Hunter Offroad
* removable Aluminum dash assembly
* custom built door skins (required with cage side support tubework
* hood pins for 4 pin removable hood
fd_017_Medium_.jpg

fd_007_Medium_.jpg

IMG_6847.jpg

IMG_6838.jpg

fd_008_Medium_.jpg




Interior
4 Corbeau bucket seats
4 Crow 5 point wrap-around harnesses
Auto Meter instrumentation gauges (Tach, Speedo, Oil pressure, Water, Fuel, Voltage, Transmission Temp) see writeup
12 Position Auxiliary fuse panel (see writeup)
Kenwood Receiver
Sirius Stiletto dash mount
Garmin Extrex Legend dash mount
CB radio
Full Recovery & Safety Gear + tools, parts


IMG_6846.jpg

IMG_6840.jpg

fd_016_Medium_.jpg

IMGA0079.jpg

91012.jpg

91011.jpg

fd_014_Medium_.jpg

fd_013_Medium_.jpg



Here is my 3 step process to access all tools/cargo until I get a tire carrier of some sort built
tools/camping chairs/spare parts safely secured
fd_001_Medium_.jpg


Spare fluids in tote that securely fits under shock mount.
fd_002_Medium_.jpg


Tire just barely fits with 10PSI
fd_019_Medium_.jpg







Not sure where to list this, but I installed my Willwood proportioning valve to get the rear braking under control, can adjust front/rear brake distribution from the drivers seat
fd_015_Medium_.jpg


ROCK ON! Thanks for looking.
4wheelin042Large.jpg
 
Last edited:



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We'll check for ya next t-haven... I know a nice rock to test sliders on:D

Just don't get high centered, like me:(
 



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I updated the first post with some of the latest mods.

Short of one of the front fenders being tied together with military 550 cord since I'm holding off on repainting the new set until I decide on color, the truck has never been more ready for the trail.

I think for the first time ever I even have a legitimate CB mount

fd_013_Medium_.jpg


Only other issue is my vision out the rear window with my spare tire wedged in here, but the more I look at it, I don't really think I want some big clunky tire carrier. I think a tire mounted on the bumper would block just as much vision and I'm beginning to hate the look (I'm more of a stealth guy myself).

fd_019_Medium_.jpg
 






Holey moley, just be thankful it fits!!

Spares are tough... hmmm any room underneath? LOL
 






about time u got a real cb mount
 






yeah, who would have thought, drill a hole in the bumper :rolleyes:


Oh, and I made another junkyard run to pick up spare parts. Snapped my 1/2" breaker bar trying to get a radius arm loose to pull the middle shaft out of a junked truck, couldn't find a 2nd gen without front end damage anywhere to get the header panel and forgot my hi-lift handle someplace.

Everything productive just about canceled out the non productivity.
 






good job dan
 






hey what if you cut the floor of your cargo area so your spare can drop down much further for visability????
there's nothing under there I dont think except bumper??
 






You have no idea how much I love the setup you've got there Danny. Makes me want a 4x4 twice as much!!:biggthump
 






hey what if you cut the floor of your cargo area so your spare can drop down much further for visability????
there's nothing under there I dont think except bumper??

that is 100% what i am thinking about doing but with 2 33's side by side.
 






Now that is one hell of an idea. I'm also thinking about seeing if I can get rid of the cross bar connecting my shocks, the one with the sexy bend in it that is completely screwing me on all facets of wanting functionality of the cargo area. What better functionality would there be than having the spare tire drop down 10" in a welded in subframe that is flush with the bottom of the rear bumper.

Sacrifice NO ground clearance, no raising center of gravity by putting tire on the roof and no departure angle killed from a tire on the back door.

I like that Idea a lot Jamie. That area was reserved for a fuel cell, but if I ever get to that point I can rework things.

I thought of this same concept on my old truck after I put the 3" body lift on, I was thinking I could put in a subfloor under it.

Here is the clearance of it, this pic is of my rock lights, my head is by the rear diff looking back.

fd_011_Medium_.jpg
 






start hacking!!

I dont plan to have a tailgate on the BII anymore, just not enough room
No way the tire goes on the roof, thats 35" of pure suck to lift/COG and I may go 37's :)

I do need a 3rd seat now, so things have gotten worse!
we should have one truck that carries everyones spares to the base of the trail LOL
 






Now that is one hell of an idea. I'm also thinking about seeing if I can get rid of the cross bar connecting my shocks, the one with the sexy bend in it that is completely screwing me on all facets of wanting functionality of the cargo area. What better functionality would there be than having the spare tire drop down 10" in a welded in subframe that is flush with the bottom of the rear bumper.

Sacrifice NO ground clearance, no raising center of gravity by putting tire on the roof and no departure angle killed from a tire on the back door.

I like that Idea a lot Jamie. That area was reserved for a fuel cell, but if I ever get to that point I can rework things.

I thought of this same concept on my old truck after I put the 3" body lift on, I was thinking I could put in a subfloor under it.

Here is the clearance of it, this pic is of my rock lights, my head is by the rear diff looking back.

fd_011_Medium_.jpg

Buy a stock sized bladder from Summit or Jegs and encase it with sheet metal. BAAAMMM fuel cell that will fit in the stock location which is 100% the best location for it. Cheap, easy and practical.
 






start hacking!!

I dont plan to have a tailgate on the BII anymore, just not enough room
No way the tire goes on the roof, thats 35" of pure suck to lift/COG and I may go 37's :)

As long as I offroad an Explorer it will have all the doors and roof, if I want an open top I'll likely buy a vehicle that started life as a convertible.


I do need a 3rd seat now, so things have gotten worse!
we should have one truck that carries everyones spares to the base of the trail LOL


storage.gif



You just need to use every nook and cranny in this setup with 4 seats fully functional I have(lucky for you I just packed the truck yesterday)

front and rear driveshaft
2 sets of front spares
spare steering
2spare spindles
hi-lift
stock jack
hydraulic jack
air compressor
2 camping chairs
4 towels+ misc rags
tote with a gallon of coolant, gear oil, tranny fluid, brake fluid
1 quart of steering fluid, 3 quarts of motor oil, 2 cans of carb cleaner & a funnel and fill tube
2 spare hubs
brake line flaring kit
brake line bender
fuel disconnect tools and gauge
1 spare brake hose
3 misc spare brake lines
shovel
2 spare belts
4 spare u-joints
4 spare front wheel bearings
spare axle seals
pouch w/ 2 sets of spindle nuts, spindle nut tool, pitman arm puller, pitman arm, hammer, caliper slide pins, spare brake pads,
pouch w/ 1/2" drive socket set, c-clamp, vice grips, D-ring
spare battery cables
25" breaker bar
complete socket set w/wrenches up to 5/8"
roll up pouch w/ punches, pickle fork, 11/16 through 1 1/8" wrenches, 2 sizes brake line wrenches, magnet tool,
3-in-1 balljoint, u-joint press tool
electric meter
electric supply box w/bulbs, fuses, wire, crimper, connectors
box w/ spare nuts and bolts, mostly stuff I grab when taking apart Explorers in the junkyard
full first aid kit
20' tow strap
binoculars



still need: rear axle shafts, spare lug studs and nuts, onboard air tank, onboard welder but I have plenty of room for it once I track this stuff down.

Also stowed is approximately 15 liters of water (30 pint sized bottles) lined under the seats for "just in case" situation, rotated out about every 6 months
approximately 2,000 calories worth of cliff bars





& I even have a container of ready wipes easily accessable at all times through the rear window.
 






drop it Dan... you'll lower your center of gravity...
 












thats not a bad idea, I was thinking about a tub like that, but instead I'm going to try to design something that is rectangular, might as well get every square inch of usable space even if it's just room for some rags or a jack stowed away.


BUT after Moab I've got some bigger tasks to tend to.

I thing my engine is in trouble and I managed to rip a caliper off the rear axle.
 






I thing my engine is in trouble and I managed to rip a caliper off the rear axle.

that gives you an excuse to change those calipers out.. I know how much you loved the ones there were on there.. :)

~Mark
 






So here's a carnage shot of my rotor situation from Moab.

IMG_0229-vi.jpg


IMG_0220-vi.jpg


And I just backed the truck off the trailer as we needed the trailer for something at work.

It took a jumpstart to get it running, wouldn't stay running at idle, the wipers were going on by themselves all crazy again, strong odor of gas, the battery gauge was dancing with the throttle up to and over 18volts, tons of blue smoke.

So this sounds like it's going to be more than one thing to chase down.


I'm going to run a compression test when I get around to it.

Very likely my complete front end cage in project will result of pulling the engine...or I will be making a trip to Texas
347_smiley_face_cowboy.jpg
.
 






I've got that spare 4.0L if you need it.
 



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we shall see, if I can't get something local I may run over and grab that, everything makes sense (low fuel volume, leaking gas, low power, hard starting, running hot) except the stupid voltage and wiper situation.
 






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