The Black Hole

[donalds]

Finished up making the shroud this evening. Ran out of time to get it installed. That's how life is lately. Plan plan plan, & do what ya can.

To make this work, and get the sides to sit flush against the Rad, more cutting & welding was required.

The 5.0 shroud is way too big (depth) for a 3" body lifted 5.0. I had to cut the top horizontal lip down to 3/4" in depth, which matches the sides, same as the 4.0L top is.

The bottom of the shroud. Well, to get this to not drop past below the radiator, I removed a few inches off it. 3" to be exact. This left no horizontal wall, and the box was only 3 sided to the Radiator. So.....

View attachment 341611

I used the upper cut off portion removed, (left side on the above pic) to make a new lower wall. The shroud is curved, with the center being the high point of the radius. I just traced the curve with my Milwaukee octopus ink pen, and cut it to shape with the Dremel cutting wheel. It was almost long enough. Left 1/2" gaps on both sides. No problem, just made some filler pcs from the scraps. Looks a little out of shape, but that doesn't matter. When I cut this pc, I left it a bit higher, so I could use the extra material to weld with on the outer seam. Worked out beautifully.

View attachment 341612

Welded in the lower wall on both sides, then the end fillers all around. Strong as new, or strong enough for this use. Nothing structural about it, so I'm good with it.

View attachment 341613

The caution fan lettering is now on the bottom. LOL

I might have to tweak one corner for the lower Rad hose and the extended fan shield, for the upper hose. That 3" body lift makes things interesting with this taller Radiator. So much easier with the smaller 4.0L Rad, and being able to drop it with brackets.

Hopefully this works. If not, I'm only out a few bucks, and a few hours of Life.

View attachment 341614


Placing it into position for mock up, it looks like there will be 1" of exposed radiator at the top. I can live with that. Good enough for this old man.

Skills!!

I love my plastic welder

 

[gmanpaint]

Anybody following this thread know if torque monsters will clear the steering shaft with the 3" body lift?

Got a line on a good set, but not sure about them working or not.

Edit: Was able to spend some time after work, and dig into this subject on the forum. Never mind.

Looks like I am going to learn how to install these TM's, using the how to write ups already here.

Pic for attention.

 

[Turdle]

I know how to do that stunt. The headers that is.

 

[vroomzoomboom]

I know how to do that stunt. The headers that is.

you even know someone that has headers that have been clearanced for a 3 inch bodylift

 

[gmanpaint]

I know how to do that stunt. The headers that is.

you even know someone that has headers that have been clearanced for a 3 inch bodylift

Dont everybody hold back on my account. Let the info flow out, like a morning after White Castles.

 

[vroomzoomboom]

Dont everybody hold back on my account. Let the info flow out, like a morning after White Castles.

you will need to ask mr. smith about this lol

 

[boominXplorer]

The interference depends on the thickness of the steering extension adapter w/body lift. The adapter will probably need to get tossed out and you just redrill a hole in the steering shaft to do without it.

 

[gmanpaint]

@boominXplorer It would need a longer intermediate shaft, as it doesn't reach the column w/o the adapter.

I did grab a double U-joint (cardone style) intermediate shaft out of a Torsion bar Ranger a couple weeks ago. It might be longer fully extended. Need to put it side by side with the Explorer shaft and see for sure.

 

[boominXplorer]

You can redrill the upper shaft hole 1" down and it will reach with no adapter. There's enough slack for a 2" body lift in the stock shaft but not 3" body lift.

 

[gmanpaint]

@boominXplorer
I will have a look at the column and see what your talking about.
Thanks!

 

[gmanpaint]

Looked at the upper column, and the top of the intermediate shaft. Can't wrap my head around the drill a new hole thing.

So these used Torque Monsters....

Seller said they was the -01 set, which is what TMH lists as the EGR set, which is what I have. External EGR on the 98.

Well, they are not the -01, they are the -00 style. So now I have 2 issues to deal with.

I sent Bob a PM here on the forum, asking if he would sell just the bung and insert adapter. Will have to call him, as it's been over a year since he has been here. The thinking is since they are just mild tube steel, a Mig weld would work, but a Tig weld would be best.

I can tell the previous owner had leaks with these. The flanges are pitted on the mate surface in spots, and the carbon is present on the outside of the tubes at the flange. I will want to have them machined flat prior to use. They don't look bad overall tho.

I found out that TMH does make, and sell a set, for a 3" body lift too. I wish I knew that prior to these used headers.

OK, so what do you all think? Are these worth the trouble?

 

[CDW6212R]

You can file the flanges fairly well yourself if they are reasonably flat. The EGR bung may not be that bad, but placing it could be interesting. You might end up with a better EGR fit than the original spot, but that depends on the EGR pipe you use.

 

[gmanpaint]

You can file the flanges fairly well yourself if they are reasonably flat. The EGR bung may not be that bad, but placing it could be interesting. You might end up with a better EGR fit than the original spot, but that depends on the EGR pipe you use.

I planned on using the existing stock EGR pipe. I seen it has to be manipulated a tad bit to work.

 

[CDW6212R]

I hope that works out well. I've only done one EGR pipe, and it was my stock Mercury, but the pipe was an aftermarket kind with no adjustment section to it. It fit well enough, I had to start both ends gently and barely, then snug them up evenly.

 

[gmanpaint]

I will circle back to the Headers after I get time to figure out the EGR add, and the steering shaft interference. For now, they are shelved.

Today I had some time to mess around with this rig. I decided to attack that sloppy Intermediate steering shaft, and try the IFS SLA Ranger Shaft out.

About a year ago, This rigs R&P blew on a trip, and a Mechanic swapped it out in Kansas. Well, he must have had a heck of a time getting it off. Not sure if it was stuck on, or he thought it came straight off the rack, instead of up, then back. He beat the snot out of it. It's just aluminum, so it doesn't survive a hammer and screwdriver to well. Not sure if this is what caused the slop in it or not. Can't remember if this gap is supposed to be there, but I don't remember it like that!

Once off, I placed it next to the Ranger shaft to check the differences.
The Ranger shaft is over 1" longer. This helps a lot when you have a 3" Body lift.
The lower female end is the same shape, and orientation.
The upper Female end is almost the same.
They use the same upper & lower bolts.

Both fully extended, in the next 2 pics. Both have the same amount of slide travel.

Ok, so here is what I really like about swapping to the Ranger shaft. it has a mini double Cardon U-joint on the lower end. No more Ball and socket to wear out. This will be my 3rd intermediate shaft now, and hopefully, the last!

So, the top female end.... The Ex top has an expansion slot to install over the shaft end, and closes up tight with the bolt.

the Ranger does not have this slot, and is solid. I had the hardest time fighting it, and it just wouldn't go on, no matter what. So....

Pried it open a tiny bit, then tapped it on, over the steering shaft end. Bolted it all up, and Bam, tight as a frogs ass. No more slop.

This was a $10 mod. To me, it's an upgrade, as I hated that Stock shaft with that ball and socket. A Steering extension can only be had, if you buy the entire BL kit, last I checked. This is one way around that expense.

 

[CDW6212R]

That is very well done, a nice little upgrade.

 

[gmanpaint]

TMH update:

After 1 unanswered PM here on the forum, a call with no answer, and a filled mailbox unable to leave a voice message, I sent Bob at TMH an email asking to sell me the EGR parts. A few days later, he replied.

He wants me to send the Pass header to him, so he can convert the header himself. He said he will also give it a new ceramic coating, and include a new ERG pipe. In his price, he includes return shipping.

I am currently waiting on a reply back from him.
I thought I might as well have him re-work the Dr side for the 3" BL too. Well, depending on what he says price wise, and If he can/want to even do it. This will take any stress or worry out of this install for me, even if the total costs end up more than a new set, after it's done. I can justify this expense by the reasoning of the initial costs making me buy them now, rather than procrastinating the purchase, for who knows how long. Fingers crossed he responds with good news!

 

[gmanpaint]

Finally talked to Bob at TMH today.

He says the 3" body lift versions he makes are completely different then the non BL set. The Dr side just can't be safely converted to work, and he won't try again.

He went on to say that the intermediate steering shaft is why, which I figured as much. I explained to him that I swapped the stock shaft with a thinner diameter Ranger shaft, and it gives 3/8" more clearance. That intrigued him. He want's me to try the one I have on the Dr side and see how it looks.

Ok, so if it does indeed clear and works, I will be sending him the Pass side to do the EGR conversion. He includes a brand new pipe made for his bung adapter. He will also send a new set of gaskets.

So, if the Dr side doesn't work, I am selling these, and ordering a new set made for the 3" Body Lift.

He is at least 3 months out, and he is now doing this full time. Said the Covid situation has increased his orders. Guess everybody had the time to work on builds, and flooded him with orders.

I have a weekend run the first weekend of Nov, and I'm traveling for 10 days this month, and squeezing in 4 weeks worth of work into 3 weeks. Prolly be mid of Nov before I can even attempt the Dr side experiment.

 

[traveler]

And again!! Thanks to you there is yet another Mod/Upgrade (translate "Expense") to work on. I like that Ranger steering mod. Like you I'd rather have the double cardon, and the extra length is nice to think about as well.

Now... Should you decide to sell those headers, would they work with a 2" body lift?

 

[traveler]

And the Napa 10" extension soft line (Thanks RockRanger for the P#) I moved it away from the shock later on.

I went back a ways looking at all the work you've done and notice this post so....

Ummm....... What NAPA part number for a 10" extension soft line?