Completed Project - Turboexplorer's Full Width SAS Build Thread | Page 28 | Ford Explorer Forums - Serious Explorations

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Completed Project Turboexplorer's Full Width SAS Build Thread

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Hello everybody! It's time to start the SAS on my Explorer. It will be an awesome project and the first project of this type and size that I have ever undertaken. Up to this point the sliders where the hardest thing that I have made myself. I am open to any suggestions and or insights from anyone as the project gets underway. I have bought every last part for the build minus the hard brake lines (axles, and from master to the frame) and the flexible lines that go down to the axles. Those are all easy to make so I am not worried about it for now until I get the axles put together and can see what i want to do with those.

Now for a list of things I will be doing with the project:
1995 F-150 8.8 - I bought this used rear axle that I will strip, lock with a Detroit, convert to Explorer Disc brakes, and mount to the truck. Factory rear sway bar will be used. I will be doing a spring over conversion and will also be remaking the rear V8 anti axle wrap bars to help the leaf springs out with the leverage and TQ the V8 37's and 5.13's will put on them.
1976 F-150 HP Dana 44 - I bought this used axle and will be stripping it of the Ford factory wedges, trussing, and building custom glorified radius arms. Like DB_1 runs and like Rubicon Expresses makes. Front will also have a Detroit Truetrac LSD in it as well. This Dana 44 has 1/2" thick axle tubes.
Fox 14" Remote reservoir coil-overs - I will be building shock hoops for these coil-overs, bracing them, and tying them together across the top of the engine with removable double lock tube clamps.
1995 F-150 Steering box - This will be mounted inside the frame rail and used with the factory PS pump and will build a custom steering link from the box to the column. I picked this 1 to keep it ALL Ford and 2 because they are fairly cheap and easy and can be tapped for hydro assist at some point if I want or need it. In order to fit this steering gear I also have to remote mount my oil filter so that it has room. I will be getting rid of the factory oil cooler and have a Trans Dapt remote filter relocation kit.

Project Parts Section:
-37X13.50 R17 Interco M-16's
-Fox 14" Remote reservoir coil-overs with Eibach Springs.
-Detroit Locker for the 8.8
-Detroit Truetrac for the Dana 44
-Yukon 5.13 gears for both front and rear.
-Both axles will receive ALL new bearings races and seals u-joints etc.
-All wheel studs front and rear and spindle studs have been replaced for safety reasons. To cheap not to.
-Already had EBC brakes on it so those pads on rear will be reused and new EBC 7000 series pads for the front have been purchased.
-New front rotors wheel bearings and new Spicer ball joints, going to reuse the warn locking hubs as they work great and are in good order and easily changed later if i wanted.
-1978 Ford T-Bird calipers have been bought in place of the factory F-150 ones. They are 17% bigger in piston size so will give me a little more brake up front to help stop those 37's.
-Trans Dapt Oil filter relocation Kit and addition mount to hook to the block at a 90*.
-Currie Johnny Joints and Rubicon Express Clevite bushings for the all the link ends.
-GM 1 ton tre's for the steering with a high angle tre at the pitman arm.
-Front axle truss. (wasn't impressed with it at all so will be making some changes)
-Extending current Expedition rear drive shaft and will have a custom double cardon one made for the front.
-Metal used: 2"X.250 wall DOM for lower links, 1 1/2"X.250 wall DOM used for upper links, 1 1/2"X.375 wall DOM used for trac bar, and ALL tabs and brackets will be made out of 1/4" Flat plate by me.
-Double lock tube clamps for the shock hoop cross brace that uses 2 3/8" bolts on each. These are so It can be removed.
-All Grade 8 hardware will be used.
-All flexible brake lines will be braided stainless steel Teflon lined hoses.

I like to follow others projects and often find myself wanting more pictures so bare with me there will be A LOT of pictures of the build. I hope you enjoy lots of pictures as much as I do.

First some pictures of what the truck was! Then onto some parts pictures. Build will start shortly.
1998 XLT Explorer. 5.0L with the 4R70W trans. I have the 4406 T-Case. 3.73 gears with rear LSD. Goodyear 31's. Rock sliders and front skid plate. Links to those builds are in my signature.





And here is some video links! :) There are a few videos of me wheeling in CO with nssj2!


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I have video of the Explorer going up this optional obstacle. Its the only thing that i have been on that was so steep the trans lost fluid pick up and didn't want to push, so I had to bump it a little harder than I wanted to get it on top before the pickup lost oil. He is picking up the right front in this pic. I picked up my left front pretty good as i went up. You can see it in the video. Video also shows a glimpse of what the obstacle looks like. You can also tell in the video as i approach it. My truck is not small but you look straight down at it.


Where you see that black LJ going up is the climb I did with the broken joint, :rolleyes: In the video of the climb you can hear the little clicks every once in a while of the broken joint.


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Ok i just spent the last 3 days of my free time at work reading through this thread...and I came across your video's on youtube before I saw them here on the last few pages. Anything i say is an understatement as far as compliments. Just plain old jaw dropping awesome. I have looked a long time for someone running coilovers as i am a big fan of them. Just the way they droop and compress so easily and the way they look while flexing. I can only hope to be able to use what you have learned and experienced and put down here on this thread, and apply to mine. I would love to run coilovers, though I doubt I will be able to (skill level wise well below yours) your ex will be and is my idol :) Congratulations on what appears to be an extremely well thought out and built rig.

My question is, how much did the Fox 14" Remote reservoir coil-overs with Eibach Springs cost? I am slowly putting together the wish list and just want to get a quick price check from someone who has purchased them (if you can that is) :)

i swear to holy fmg! once you go air shocks or coil over you will NEVER go back.

Good times

Here is some of the videos from Feb 16th wheeling. The end videos mine wasn't in since the broken joint, but good videos none the less. The first section shows me climbing that wall and carrying the left front. The third video section shows the flex of the rig really well. :) Enjoy! :D

Shocks and springs ran about $500 per side. They have been great glad i did coil-overs.

Right on. Thank you sir. :) Keep up with the great videos, love to watch this rig in action!

Had some questions and comments on wheeling in St. George. I started a thread here St. George wheeling in the trips planning and discussion area to see if anyone interested wants to head out and wheel. So if your interested hit this thread up and lets see if we can't get some forum members together to have a killer time wheeling and getting to putting some names to faces.

So at some point it looks like I may have almost twisted the left axle tube in my housing. :eek: A few Sundays ago while out for a walk with my family I noticed a quarter sized spot under my rear diff. So I get to looking and sure enough the left axle tube has cracked paint between it and the housing and a tiny bit of gear oil has been seeping out of it. :mad: O well. Good news is that the tube hadn't actually turned or moved at all. Literally the paint was just cracked. So last weekend I welded up the tubes to the housing to avoid any problems down the road. That would suck to twist the axle tube in the housing out on the trail. So all is fixed and it sure as heck isn't going to twist that's for sure. Welded an inch on opposite sides of each tube at a time and gave 10 min to cool, then did the next 1 inch welds 180* from each other. Cools quick since the axle has so much mass. I also welded grounding tabs to both axle tubes before I welded them to the housing. That way I could ground it on which side I was welding. This way I hoped to avoid any arcing or current going through any bearings. Anyways enough said here is the pics after I welded them and sprayed a quick coat of black on.





Still keep an eye on it, cast metal will sometimes crack around a weld.

Will do, but cast steel has much less tenancy to do that then cast iron. Time will tell but either way it wasn't going to hold for long the way it was so this was the best option. If not then I can swap internals to a new housing, would be fairly cheap and quick to do so not to worried. But it welded awesome and really easy as if it was all mild steel. Plus factory does those big plug welds and never really see cracks from them that i know of. :scratch:

P.S. Am I the only V8 running 5.13's and 37's on an 8.8 here?

Here is my brother sector9's first gen up on the ramp! Lifting a tire in the pic but makes for a good picture.

Next time I have mine in St. George I will get mine on the ramp for some pics.

That first gen of sector9's in the pic above? No, still 100% stock TTB minus the 31's and rear shackles with coil pucks up front.

Hey guys looks like I was nominated for May 2013 Truck of the month here on the forum. (Thanks Froader) Any votes from those who like the build would be great :D

Link to the thread here: May 2013 Truck of the month

U got it!!

I still had sway bars connected front and rear too! Hope fully soon it will be getting a lift and lockers so i can keep up!:thumbsup:

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I still had sway bars connected front and rear too! Hope fully soon it will be getting a lift and lockers so i can keep up!:thumbsup:

Heck ya, can't wait! :D I made a new video that has a bunch of your rig in it as well from us wheeling over Christmas. It's uploading now, will post it up tomorrow. Bunch of different views we tried that day. But from now on the GoPro's will have the skeleton back doors so hopefully they will pick up better audio.

If the offer on the house goes through we will be taking the X down to St. George to go wheeling then drag my 2 sport quads back up here. So if anyone is interested in wheeling the end of this month just let me know. I should know tomorrow.