Project Green Hornet '01 Sport SAS | Page 6 | Ford Explorer Forums - Serious Explorations

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Project Green Hornet '01 Sport SAS

I have been at this for a little while now. I haven't really taken any pictures of the steps leading up until now. I am bad about blogging as I do things, so I will take pictures when I think to and if any of you guys have questions or input I will snap pictures along the way. I fabbed the outriggers from scratch. I used the boomerang shackles to give me more clearance around the body mount and give me a littler better ride. The front cross member was made from a 2"x3" rectangle tubing with hangers from I then bolted it to the frame in a few places as well as used it as a back mounting support for the winch. I made a dimple die to press the clearance holes and add some more strength and make them look better. I opted to use heims instead of using tie rods. I got the teflon lined 5/8 holes with 3/4" shank both for the tie rod as well as the drag link. I plan to use a pitman arm from either an astro van or a jeep wagoneer. The gear box is from a jeep cherokee which is what I got the Dana 30 from. I bought a crossover steering bracket from made specifically for the jeep dana 30/44 axles. This is a great setup which I will transfer over when I find myself a good dana 44 to swap for the dana 30 I got now. The steering shaft is a hybrid of the stock explorer shaft and cherokee shaft. It had to be shortened by about 13-1/2 inches and reinforced for peace of mind. The gear box will be drilled and tapped later for hydro assist when I find a new 44. I am still in the process of re-plumbing the box, but all my fittings should be here this week. When I do the setup for the hydro-assist I will be adding an adjustable relief valve to upgrade the steering pump pressure that I read about somewhere on this site recently. The pitman arm right now is facing to the back and is looking all kinds of hell, but don't worry I plan to flip it to the front. You can see it's got a little of that explorer detroit lean to the driver side that I will have to address at some point. I'm sure there is more to cover that I haven't covered, so just let me know what you think. Be gentle this is my first major project like this. I’m all for constructive criticism, but don’t be a dick. I will grab a bunch more pictures tomorrow in the daylight, but here is a couple teaser pics.


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One more of the rear shocks along with the rear bump stops mounted. I made it so they could be mounted using the same holes as the spring plates so if they needed to be adjusted later I wouldn't have to take the plates off too.


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Finally the bump stops being made:


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Update: I have been tweaking odds and ends getting close to having everything wrapped up. I was able to snag a 1350 manual shift with a fixed front output yoke from an '89 ranger for cheap. This should get me started until I can track down a 1354. This will give me a head start on a doubler too. :thumbsup: It needs to be cleaned up. I need some help identifying what the circled part is near the shifter. It looks beat up but I wouldn't even know what to look for. Any help would be appreciated.


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Just thought I'd chime in and say your truck is awesome! nice fab work. Good attention to detail. I have no idea what that part is you're looking for though.

Isn't that the switch for the 4x4 light on the dash

If it is the 4X4 switch can I just leave it the way it is since I don't have any need for it?

Wow. What part of TN are you in?

I cannot believe I have not seen this thread! Very very nice build sir. I have the intentions to do this exact swap (start with the d30 most likely as you did) and then progress from there. I wish i knew what that particular part is on the Tcase, but I just don't. Too bad I can't help with that, but a compliment will just have to suffice :)

Isn't that the switch for the 4x4 light on the dash

Pretty sure this is the answer.

Cookville isn't that far from me. Where you planning on wheeling this thing?

Yea, I ran home at lunch and looked at it and that is definitly what it is. It moved everytime I switched "gears". Thanks 4wheeltom.

My wife is from Lawrenceburg, so I am sure we will be doing some wheeling down there in summertown at wheeling in the country. Other than that probably Windrock and I heard there is a park in Sparta, but I don't know of anyone that has been or if it's even open or not.

Where in TN are you at?

I'm in KY. About 170 miles north of Cookville. I have been to most of the parks around here. Planning to hit Golden Mountain and Windrock this year. Haven't been to either of those yet. We'll have to hit some trails together

I was able to take advantage of the extra hour of daylight today and finished up my hydro assist steering and cleaned up the transfer case and hit it with some hammered silver which hides all the dirt and crap I didn't get off and makes it look almost new. I used a track bar bracket and OD clamp that I customized from ballistic fab for my mounting points. My hydraulic lines are a little long and look a little crazy but I have them tucked pretty good for now.


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Looks great bud! Love the tube clamp idea. Think I'm going to steal that idea from ya

Nice welds, Nice Work!!

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Well I went ahead and got it put together and drove it around with my stock 2wd transmission. It felt really good. I was a little nervous at first around other cars, but soon it was as natural as pre-SAS. There are still things to work out. I will swap in a 4x4 trans when I get the money saved back up. after that it is in need of some lower gearing BAD! The truck ran fine with the 4.10's but it was sluggish. I think 5.13's or even 5.38's would be a lot better. For now it will just be a mean looking mall crawler. Now that the weather is getting nicer I am going to try and get it out and test some of my work :D.