explorer upgrade | Ford Explorer Forums - Serious Explorations

  • Register Today It's free!

explorer upgrade

whitetrashfab

Well-Known Member
Joined
June 15, 2009
Messages
449
Reaction score
0
City, State
Tenino, WA
Year, Model & Trim Level
91 sport
Well after my last axle failure (a split bearing hub) I figured it was time to start looking for something better. After I switched to Nitro axles and joints in the 44 my axle problems have been few and far between but I cant leave well enough alone... I could just switch to drive flanges and hope that my ring and pinion arnt my next weekest link... or I could go to 60's. I have broken lots of axles, universal joints, one ring and pinion, 3 warn and two stock ford hubs, one wheel hub, and riped one spindel tube off on my 44. I have also added alot of wait with my exo cage, bumpers, tools and spare parts that I drag along with me that dont help my problem. So the other day I bought a king pin dana 60 out of an 89' f350 and today I got a rear disc dana 60 out of a 00' econoline e350 van. I plan on cutting them down and installing them under my exploder, the plan is to have them in and ready by memorial day for a trip to the naches. I will try to take some pic's along the way to share with everyone. I already have the front striped, the short side notched, and I ordered the james duff weld on wedges. I should have the front cut down by the end of next week... this "should" be a fun build... and a huge waste of $$$$:D
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





Thanks Forrest... 89' dana 60 HP KP for $750 devivered to my work;)
 

Attachments

  • 166166_1670882064829_1620716213_1625848_3962792_s.jpeg
    166166_1670882064829_1620716213_1625848_3962792_s.jpeg
    2.1 KB · Views: 772






If you hurried you could be done for a trip to Moab;)
 






I thought about Moab but I figured I could do alot of local wheelin trips for the same amount of money and alot less driving (that and getting that much time off work is hard for Becky and I). I WILL make it to Moab one of thses days....
 






I did some cutting tonight
 

Attachments

  • 167552_1699163131838_1620716213_1674304_3352935_n.jpeg
    167552_1699163131838_1620716213_1674304_3352935_n.jpeg
    28.3 KB · Views: 729
  • 179692_1699167531948_1620716213_1674307_116609_n.jpeg
    179692_1699167531948_1620716213_1674307_116609_n.jpeg
    15.9 KB · Views: 718
  • 166843_1699168771979_1620716213_1674310_2742357_n.jpeg
    166843_1699168771979_1620716213_1674310_2742357_n.jpeg
    24.4 KB · Views: 733






cut the read also
 

Attachments

  • 167516_1699280694777_1620716213_1674379_5916685_n.jpeg
    167516_1699280694777_1620716213_1674379_5916685_n.jpeg
    29.3 KB · Views: 750
  • 179266_1699281454796_1620716213_1674380_8256957_n.jpeg
    179266_1699281454796_1620716213_1674380_8256957_n.jpeg
    23 KB · Views: 734
  • 167231_1699282774829_1620716213_1674385_5401660_n.jpeg
    167231_1699282774829_1620716213_1674385_5401660_n.jpeg
    21.4 KB · Views: 737






I was suprised that the van dana 60 was made with two different driveshaft bolt patterns drilled in it, the smaller of the two is the exact same as my explorer driveshaft. I also got some stuff from james duff the other day.
 

Attachments

  • 167868_1699284534873_1620716213_1674391_5969334_n.jpeg
    167868_1699284534873_1620716213_1674391_5969334_n.jpeg
    18.7 KB · Views: 739






Got some more done over the last few nights... A friend of mine loaned me his alinement bar so I narrowed the rear. I turned the spindles true on a lathe and hand ground the weld-prep on the axle side after I made my final cut. I TIG welded the root pass and hot pass and used the MIG to finish weld out then I blend ground everything smooth when I was done.
 

Attachments

  • 179890_1719279034723_1620716213_1713631_679879_n.jpeg
    179890_1719279034723_1620716213_1713631_679879_n.jpeg
    16.6 KB · Views: 680
  • 181973_1720944076348_1620716213_1715966_2463840_n.jpeg
    181973_1720944076348_1620716213_1715966_2463840_n.jpeg
    19.8 KB · Views: 689
  • 182093_1714211828046_1620716213_1702805_5833259_n.jpeg
    182093_1714211828046_1620716213_1702805_5833259_n.jpeg
    20.5 KB · Views: 677






Frone end cut down from 69.25 to 59.25, the same as my early bronco dana 44.
 

Attachments

  • 181695_1714179587240_1620716213_1702707_6818735_n.jpeg
    181695_1714179587240_1620716213_1702707_6818735_n.jpeg
    24.1 KB · Views: 679






Got the rear finished last week. One side was right on with the alinement bar but the other ended up a little off after welding. I put some heat to it and it is almost there, I will try a little more but for what I do with the rig it dosent have to be exact. I had a hard time trying to figure out how narrow to make the rear. Most rigs the rear is a few inches narrower then the front to help steering but I think that all goes out the window when your running a spool anyway so I made it the same as the front. That will keep me just under the stupid 80" trail width with 10" wide wheels. Sounds like I have my tires and wheels sold so I will pull my axles out soon and start the swap.
 






lookin good. you need to put some 40s under that thing or maybe some 42s.
 






update... I had had some problems with how the front axle was fitting so I widened the front and rear to 63" wms (I had cut it to 59 before) and made up for the added legenth by going to a bigger rim offset. I bought 5 new 39.5 Iroks that Im going to stuff under it when the axles are finished. I am waiting for them to finish cutting my beadlock rings so I can getthe rims welded up and mount the tires. My axle shafts showed up today from dutchman so theres one more thing taken care of.
 






I got some stuff done
 

Attachments

  • 190562_1772784172318_1620716213_1794071_5723432_n.jpeg
    190562_1772784172318_1620716213_1794071_5723432_n.jpeg
    18.9 KB · Views: 580
  • 197971_1772719370698_1620716213_1793953_1541513_n.jpeg
    197971_1772719370698_1620716213_1793953_1541513_n.jpeg
    19.9 KB · Views: 588
  • 200605_1774540336221_1620716213_1797410_4916433_n.jpeg
    200605_1774540336221_1620716213_1797410_4916433_n.jpeg
    23.6 KB · Views: 569
  • 195893_1773154981588_1620716213_1795073_2588576_n.jpeg
    195893_1773154981588_1620716213_1795073_2588576_n.jpeg
    19.8 KB · Views: 568












Can you open and close your doors? It looks like you have a bar across the door. Just wondering if you get in Dukes of Hazard style... the build is lookin awsome by the way!
 






I am still working on the door bars but they are bolted to the door and open/close with them. I thought I would give them a try with my new doors... the last ones got so bad I couldnt get new glass to fit in them.
 






What type of mount for your track bar?
 






I am still working on the door bars but they are bolted to the door and open/close with them. I thought I would give them a try with my new doors... the last ones got so bad I couldnt get new glass to fit in them.

Looking forward to possibly copying your design on that. Just gotta find another passenger door first.
 






I know where there is 4 of them Kevin
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





Yeah if you get a decent design going on those doors I would like to copy you too. Post more picts of that design if you could and more picts of the axle project.
 






Back
Top