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MyNameIsAric's 98 FULL width SAS

I will keep this first post updated with my progress so people don't have to weed through all the boring crap associated with these buildup threads.
So far I have:

Front axle:
Dana 60 35 spline kingpin high pinion from a 79 f-250/350
detroit locker
dedenbear knuckles
5.38 gears
alloy usa shafts
longfield u-joints
warn hubs (should have went with drive flanges)
high steer arms with full hydraulic steering

Steering:
2x8 double ended cylinder from surpluscenter.com
steering valve out of an old forklift
misc. hoses and fittings from surpluscenter.com

Rear axle:
Dana 60 30 spline low pinion from a 79 f-250/350 (should have went with a 14 bolt)
full spool
5.38 gears
Disk brake conversion

Tires/wheels:
16.5" hummer h1 8 bolt double beadlocks recentered with custom stazworks centers.
36x12.50 wrangler rt II 6 ply military bias tires(sucky but cheap)

Things I need still:
new rims and tires and hopefully she wont shake so bad at 60mph.


Got axles
IMG_0923.jpg


Got a new truck so i can dismantle the explorer and tow it around when i'm done.
Welded Diff covers
IMG_1817_1_.jpg

PIC-0127.jpg

Rear axle almost done
IMG_1818_1_.jpg

PIC-0124.jpg

Front axle almost done
IMG_1819_1_.jpg

Rear axle under truck
PIC-0183.jpg

Welding up rear driveshaft (yes, it is square)
Photo-0059.jpg

Photo-0058.jpg

Machined parts for the upper control arms
Photo-0060.jpg

Photo-0061.jpg

Photo-0062.jpg

Photo-0067.jpg

Photo-0069.jpg

Made coil buckets
Photo-0068.jpg

Made lower control links
Photo-0070.jpg

Photo-0072.jpg

Photo-0073.jpg

Photo-0074.jpg

Mocking up Front axle and welded up hydraulic ram mount.
Photo-0076.jpg

Photo-0077.jpg

Photo-0078.jpg

Photo-0079.jpg

Photo-0083.jpg

Got myself a forklift orbital for my hydraulic steering
Photo-0084.jpg

Photo-0085.jpg

welded on lower control arm mounts
Photo-0093.jpg

Dropped the front IFS
Photo-0094.jpg

Sent it to the scrap yard
Photo-0096.jpg

IFS gone
Photo-0097.jpg

Front axle starting to go in.
Photo-0102.jpg

Photo-0105.jpg

Photo-0104.jpg

off jackstands
DSC00186.jpg

DSC00188.jpg

DSC00190.jpg

Photo-0106.jpg

Took out the A/C system and cruise control. Also removed ABS brake controller, but I ended up having to put it back in later for the speedo to work.
DSC00193.jpg

Mounted new/slightly larger fluid reservoir for the hydro system.
Photo-0271.jpg

Mounted the stock power steering cooler for the hydro system
Photo-0272.jpg

Got this mounted in the engine bay where the A/C junk used to be
Photo-0085.jpg

Had to chop down this thing first though.
Photo-0275.jpg

Made some tie rods out of 100% grade A beef.
Photo-0280.jpg

Installed hydraulic ram and tie rods.
Photo-0301.jpg

View of the filter, and you can see the high pressure hose running from the pump down to the steering valve.
Photo-0302.jpg

This is how i connected the stock steering wheel to the steering valve. 3/8" swivel
Photo-0304.jpg

Better view of the steering valve.
Photo-0306.jpg

Poor planning caused track bar issues
Photo-0307.jpg

Made a new track bar bracket
Photo-0311.jpg

Cut off first track bar bracket
Photo-0320.jpg

Plated for good measure
Photo-0321.jpg

Welded on new track bar bracket. Still had minor interference so i move the axle forward another 1/2"
Also started putting on shocks.
Photo-0352.jpg

Photo-0356.jpg

Photo-0357.jpg

DSC00963.jpg

Tacked a tone ring to the rear d60 carrier
Photo-0360.jpg

Reinstalled tone ring sensor so i can get speedometer back
Photo-0361.jpg

blah blah blah tidied things up and poof.... an explorer that can only go 55mph now. If you have questions, just ask or PM me.
 



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mynameisaric

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Year, Model & Trim Level
98 XLT
Callsign
KD9OWX
well i have shock towers and new coil buckets. going to try and do the coil buckets thursday/friday after work. and the shock towers this weekend. but in all reality 24/25th isnt going to happen. i need driveshafts too. these square things were a bad idea. too much slop. i'm going to keep it for a spare, but i cant use it full time.
 



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RFR2212

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Weaksauce! Get it done. I think theres a run to the cliffs in October. It's supposed to be a noob run, so it may be good for a shakedown run.
 












mynameisaric

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Moved the trac bar.

Started by throwing some tinfoil over all the rubber lines to protect them from flying plasma cutter slag.
Photo-0318.jpg


Cut the old one off.
Photo-0319.jpg


Cleaned up the frame.
Photo-0320.jpg


Plated the frame for good measure :thumbsup:
Photo-0321.jpg


And apparently I forgot to take a picture of the finished product..... :rolleyes:
IMG_NO_FILE_/IMG

Fixed my coils. Used the old buckets. drilled a half inch hole in the center and used the retainers to clamp in place. My truck doesnt squeak when i bounce it in the driveway. When i drive it around the block i can hear all the other noises i need to fix.
Photo-0338.jpg


Bought a winch for $400
Ramsey RE12000
Way overkill, slow line speed, but supposed to be bullet proof. Needs a little work though, and a cable.
Photo-0337.jpg


The guy threw in his winch mount/brush guard for his old excursion. So i'm going to sell this and bring down the overall purchase price of the winch.
Photo-0333.jpg
 






RFR2212

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Possible wheelin trip on Halloween weekend. There's your next deadline ;)
 






GRNMACHINE

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Nice Welds!!!
 






mynameisaric

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thanks grnmachine! Measured for shocks this weekend. just ordered 4 es9000 shocks last night. just need to call around for driveshaft shops for a real rear driveshaft.
 






GRNMACHINE

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The ES9000 shocks have been decent especially for the money. They were Super Cheap. Was told a driveshaft place in Alsip area did decent work-never ever used them though.
 






RFR2212

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Suburban driveline in Villa Park does excellent work. They're on North Ave only a few miles easy of 355
 












RFR2212

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Too bad you couldn't have had this together. I flopped the jeep!
 






mynameisaric

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well a flop is better than a flip. how bad is your rig?

AND, i was working on it tonight. buttoned up a few small things. Had to replace the return line rubber hose. The crap i got from o'reilley's was swelling up and starting to split. so i bought a whole spool of what i thought was transmission hose (turned out to be fuel line hose, so we'll see how this stuff works out) from autozone and replaced the line. I have all my measurements for where i need the shock towers to be and such, so hopefully i'll have shocks this weekend if i can find some time.
 






RFR2212

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It was easy.... Only some scratches in glass and dented a shock body from the brake line caliper bolt. Oh well. It'll last. I'm pretty sure I'm done wheelin for the year. I forgot to get my brakeline part numbers to order new ones and it's in WI. Oh well..
 






mynameisaric

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well i hope mines done by winter! I'm just being ridiculous if its not done in the spring. so we'll go wheeling for sure in the spring.
 












mynameisaric

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2 of 4
Photo-0356.jpg

Hopefully it doesnt rub since i out-boarded them.....
Photo-0357.jpg


Almost got the other front shock done, but i need lower tabs... I messed up on the quantity for some reason... i need to stop buying things at 3 am....
 






rookieshooter

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Coming along very nice. I think the shocks wll do just fine.
 






mynameisaric

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Thanks Rookie!

3 of 4
DSC00963.jpg


I still have the factory shock on the other rear corner.... so technically i have shocks on all 4 corners now :D
 






mynameisaric

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Slap one of these on
Photo-0360.jpg

Put this in the diff cover (on a side note, the giant hole in the top for the sensor makes a very convenient filling location when you're trying to pour in 20 degree 80w90)
Photo-0361.jpg

Still need to make my abs unit look like the thing circled in red and hope for the best.....
abs_controller1.jpg
 



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mynameisaric

Explorer Addict
Joined
January 18, 2004
Messages
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Location
Illinois
City, State
Bolingbrook, IL
Year, Model & Trim Level
98 XLT
Callsign
KD9OWX
hooked the ABS controller back up and drove it down the street.... and..... my speedo works!

However, my hydraulic steering valve leaks now. :( Planned on going off road this weekend, but with the leak, there was no way i'd be able to do anything without pissing Mercon V all over the trails, and having to refill the reservoir every 10 minutes. Time to research where to get parts at for these things....
 






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