Completed Project - New Navajo Truggy build | Page 16 | Ford Explorer Forums - Serious Explorations

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Completed Project New Navajo Truggy build

Use this prefix for completed projects that are not "How to" articles or threads asking for help.
Started fabrication on the trac bar. I wanted to upgrade my frame mounted joint to a 3/4" bolt. This meant using a 3" Johnny Joint. I ordered a weld on type. The tubing thickness is .188" wall
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I used my positioner to spin the pipe. It was quite interesting working its foot peddle, the tig welder's foot peddle, Torch in right hand and feeding wire with the left. This all coming from the guy that can't pat his head while rubbing his tummy.
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Here is a tool i made up to install the Poly assembly of the Johnny joint. It also works in reverse
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Fabricated Headers

Just finished fabricating my headers. My goal is to run side pipes with exhaust cutouts. To make things simple I used a "Lakester Header" type megaphone tapered tube and merged all the exhaust tubes and ran it outside the frame. Some fancy offsets on the drivers side to clear the steering shaft. I also used V grove SS band clamps for the collector (no gasket).

I used an old set of BBK headers for the flange at the engine. These didn't fit because the explorer uses GT40P heads. I wanted to run mine outside the frame anyways.
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Is there anything you cant build??

Always amazed by your work!!!!
 






Progress photos

I've been plugging away at the V8 swap. Of course I can't just throw in a V8. I cut out the cross member completely. Cycled the suspension and got another 3" of bump travel. That made me redo the bump stops, notch the frame for the track bar, make a new pitman arm etc.

Upon full bump my drive shaft hit my fabricated cross member. Her is it after I notched it for clearance. I also had the Yoke of the drive shaft "trued" to gain clearance

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Bump stop mounts

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Sneak peak of new look


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Vacation is the 2nd week in July. I need to haul all to finish
 






Wow! That's all I can say, just wow!
 












Updates

Well I finally got the 5.0 running. I've been busy trying to get the front mustang clip to work.

I also found out that my amount of wheel travel is causing my front driveshaft to bind. My solution was a custom high angle CV capable of 51 deg and having my T-case adapter machined so I can clock it away from my trans pan.

Here is a sound clip and some progress photos. Planning on bringing it to Havasu for thanksgiving.

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WOW just made it through all 16 pages of your build. very impressed with your skills. Some great ideas for my new project a 93 ex limited that I just picked up for $200 with a fresh built engine and the front suspension already removed...
cant wait to see how the mustang clip works out...
 






Motor sounds great! From the last pic I take it you're running a second gen Explorer engine/ electronics?
 






Motor sounds great! From the last pic I take it you're running a second gen Explorer engine/ electronics?


The 5.0 and Trans is out of a 2000 explorer. I got the ecu reprogrammed for PATS delete, all smog related components delete, premium Fuel, Trans shift improvement. $450

Harness professionally cut down. $400

Advanced adapters to mate dana 20 transfer case. Twin stick shifter.
 






The 5.0 and Trans is out of a 2000 explorer. I got the ecu reprogrammed for PATS delete, all smog related components delete, premium Fuel, Trans shift improvement. $450

Harness professionally cut down. $400

Advanced adapters to mate dana 20 transfer case. Twin stick shifter.

No more 5 Speed? That is a pretty stout auto but I figured you might stick with a manual being you had the truck swapped for it.

If you don't mind telling who did the reprogram? I'd like to ask them if they have the ability to remove all Trans functions to allow the truck to run properly with a M50D-R2 behind that Explorer 5.0. I know physically it works and people have done it, but I'd like to pass inspection here in NJ (Can't have CEL).
 






No more 5 Speed? That is a pretty stout auto but I figured you might stick with a manual being you had the truck swapped for it.

If you don't mind telling who did the reprogram? I'd like to ask them if they have the ability to remove all Trans functions to allow the truck to run properly with a M50D-R2 behind that Explorer 5.0. I know physically it works and people have done it, but I'd like to pass inspection here in NJ (Can't have CEL).


To get your computer reprogrammed however you want. Call Juanco.
His name is Juan.
The company name is Juanco.
(619) 843-9819
 












Progress photos

Getting closer. I have a few remaining issues.

1. I need to replace my condenser. This is not good news because the AC box was installed BEFORE the engine went in. I'm not sure it can be removed without yanking the engine. Keeping fingers crossed.

2. My engine keeps going into "limp mode". The engine runs great, but as soon as I start accelerating aprox 2-3 MPH the engine goes limp. This lead me to buy a WIFI adapter for the OBD2 port. This allows me to read and clear trouble codes, watch engine parameters from my IPAD. I guess the IPAD is part of my dash lay out now.

Transmission leak. It appears that the rear of the transmission is leaking by that adapter I bought from Advanced Adapters.



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Succesfull first trip

My son and I just got back from Glamis over Thanksgiving weekend. This was the first trip out on the V8 swap.

The engine ran awesome. We made it up Oldsmobile hill with no problem. Didn't overheat, ping, miss or anything. The ac did however loose its charge the first day. I need to replace the evaporator AGAIN.


http://youtu.be/NAqdM1HsHI0
 












Pure awesomeness.
 












Looks like a really fun truck, and I'm interested to see how the Mustang front turns out. But I can't help but say that it looks like the seat and harness are way too big for your son. Not trying to sound like I'm undermining your concern for safety at all, just thought I'd mention it. I've ridden in trucks where the harness is way above my shoulders and it is not fun when the front end begins to pogo-stick over whoops.
 



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Can't wait to see the revisions in person. I hope you can join us at Truck Haven in January:chug:
 






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