• Register Today It's free! This box and some ads will disappear once registered!

well I've finally bit the bullet SAS

well I've finally bit the bullet: Curtis' 3-link SAS

I'll be picking up my D30 from a TJ with 4.10s (to match the 4.10 i already have) plus, its 50% day at the JY :D i will be making my own custom three link, using ballistic joints on the frame side & Rustys superflex joints at the axle, lower links are 1.5" DOM .120 wall sleeved with 2" DOM .250 Wall. Third link is 1.5" DOM .120 wall with a Creeper joint at the frame and stock jk end on the axle.

bracket.jpg

bracket2.jpg



Ill also be using an adjustable track bar from an XJ that im getting for free, the coil buckets are from ballistic and the shock towers are f250 ones. The steering box will be from an ifs Toyota with a trailgear pitman arm, the return line is stock while the stock pressure line was lengthened, ill also be using a hybrid shaft from the toy box and stock explorer shafts. all the steering on the axle will be chevy TRE over the knuckle with 1.25" .250 tubing and the drag link is the same tube with 3/4 heims. Brake lines will be from Rustys, going to use Wild Horse EB 5.5" springs and shocks are Bilstein 5125 12" travel and im going to SOA the rear with the stock shocks mounted in the top sway bar hole.

I moved the axle 3" forward for a wheel base of 105" and will be using a hybrid driveshaft from a first gen and my 95-96 front shaft. Now has 35/1250/15 new MTR's on 15x10 black wheels (don't know what kind) and kept the spacers up front.

And my 4.10 front diff and 2" body lift with custom brackets will be for sale, if anyone is interested PM me

Im sure ive forgotten something but heres the budget brake down so far:
Axle $60
Mounts $100
Custom 3 link $200
Dana 30 Lock Right $75
Axle Seals & Synthetic Gear Oil $70
8.8 Aussie $280
Ruffstuff 8.8 diff cover $135
Ruffstuff D30 cover $125
35" MTR's $714
Wheels $0
Extended stainless brake lines $62
Steering box $50
Shock towers $60
Ballistic buckets $85
WJ brake swap $300
One ton steering $200
Sliders $150
Shocks $175
Misc Items (cutting wheels, welding wire, bolts, etc) $100

Total so far $2981

pics to come.
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month "try out" option.

Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private conversations, and more. Join Today. Your support is greatly appreciated.




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
got my tax money back so i bought the link brackets and decided to go head and pick up an aussie for the 8.8 and a ballistic diff cover.

Im waiting to see if a friend of mine has the two lower arms i can cannibalize and use.
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month "try out" option.

Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private conversations, and more. Join Today. Your support is greatly appreciated.




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
everyday this build changes. got some more toys today.

diff.jpg


aussie.jpg


ruffstuff diff cover from east coast gear supply, 3/8" steel with a 1/2" ring.

and this is how she sits now since i have an f'ed up body bolt :rolleyes:

truck.jpg


i got the arms from my buddy, just need to get some poly-bushings, steering box & lines, and have ordered a trail gear creeper joint for the third link.
 




Twiztid

Well-Known Member
Joined
June 4, 2006
Messages
497
Reaction score
0
City, State
Springfield, Mo.
Year, Model & Trim Level
88 ranger 96 ex 5.0 2wd
you have a pm
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
frontaxle.jpg


not that there is much interest in this build, but im documenting non the less. front axle is out.

the arms i got are 2" OD, .370 wall with large Rubicon Express joints on each end. the coils are rubicon express 5.5 TJ coils
 




machinest

Member
Joined
November 26, 2008
Messages
12
Reaction score
0
City, State
Belton Mo.
Year, Model & Trim Level
94 Sport
you should have found a D30 from XJ Cherokee high pinion non disconnect thay are 30% stronger than a TJ. Correct rotation! and Cherokee springs do not have enough spring rate for an explorer. Check your door tag and check a grands door tag, you will see a big difference in the front gvwr. We have frames, they are car like, you know, frameless.
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
reason behind a TJ axle is that it already came with 4.10's (aka saved me around $350) it is a non-disconnect axle. lp & hp dont really make too much of a difference at this point. but i want cherokee springs because they are softer, because i ultimately dont want it to sit really high, im going for a lower COG. and the springs i got flex amazingly.

heres a pic of my buddys jeep they came off, granted the tire is in the air and he was limited but his worn out poly bushings. that cherokee has 37s on it.

johnsjeep.jpg
 




james t

Elite Explorer
Moderator Emeritus
Joined
January 27, 2002
Messages
10,667
Reaction score
9
City, State
Texarkana AR/TX
Year, Model & Trim Level
94 SAS sport
Do you have a "spring backup plan" in case you dont like 'em? Just saying... the explorer has about 800-1000lbs more sprung weight than an XJ and whats soft on an XJ is going to be super-duper soft on an Explorer.

Either way, its a cool build... keep up with the documentation you'll find most of these threads dont really take off until the pics of work being done start piling up. :D
 




machinest

Member
Joined
November 26, 2008
Messages
12
Reaction score
0
City, State
Belton Mo.
Year, Model & Trim Level
94 Sport
what will happen is like if you take a ball boint pen spring in your fingers and compress it. it will bow and buckle under the weight. And the taller the coil the worse it gets. A 4in over explorer coil is shorter than a stock XJ or ZJ coil. If you do put the XJ coils under it watch for bow and stand back and hope they dont shoot out! if your upper spring bucket is centered over the lower at ride hight there is less chance of that but! the arc of your control arms can change all of that. the longer the better for you
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
Do you have a "spring backup plan" in case you dont like 'em? Just saying... the explorer has about 800-1000lbs more sprung weight than an XJ and whats soft on an XJ is going to be super-duper soft on an Explorer.

Either way, its a cool build... keep up with the documentation you'll find most of these threads dont really take off until the pics of work being done start piling up. :D

yea, i have a couple ideas on springs. what im going to do is SOA the rear first and adjust the front according to the rear height.
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
ummmm, i think im missing something here?

26143_737564527833_22219908_4139146.jpg


started front dissasembly tonight, and if i could ever work my correct schedule at work i could get my flipping garage wired for 220.
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
rear is done, just need u-bolts, this thing is tall as all hell! stock 4 door leafs with no overload and stock length shackles.

truck-1.jpg


plasma cutter is up & running too, now to start cutting :bounce:

forgot to add i picked up this little number
cover.jpg

ruffstuff dana 30 cover
 




james t

Elite Explorer
Moderator Emeritus
Joined
January 27, 2002
Messages
10,667
Reaction score
9
City, State
Texarkana AR/TX
Year, Model & Trim Level
94 SAS sport
Hell yea. :thumbsup:

Having the rear done is good motivation to get done with the front. :D
 




rookieshooter

Moderator Emeritus
Joined
March 13, 2005
Messages
7,290
Reaction score
1
City, State
Martinsburg WV
Year, Model & Trim Level
84 BII "Li'l Samson"
Yes sir, you got your motivation now. Looks good.
 




91ROKKRAWLER

Well-Known Member
Joined
December 6, 2007
Messages
511
Reaction score
1
City, State
Bend, OR
Year, Model & Trim Level
'91 Xploder
Subscribing, interesting build. I wanna know how much the tj30 holds up to a lunchbox locker. What size tires you planning on running?
 




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
Subscribing, interesting build. I wanna know how much the tj30 holds up to a lunchbox locker. What size tires you planning on running?
yea we will def find out, i plan on having plenty of spare parts for it since they are easy to come by because most of my friends have a d30. im gonna eventually run 35/12.5/17 with an aluminum wheel to save weight. I finally got out the nice camera

sas1.jpg


sas2.jpg
 




section525

sextion525
Elite Explorer
Moderator Emeritus
Joined
February 11, 2001
Messages
14,777
Reaction score
26
City, State
Red Bluff, Ca
Year, Model & Trim Level
1975 Ford Bronco 4x4
Booyah! No going back now! :cool:
 




Trckmagik

Ole Bag
Moderator Emeritus
Joined
August 22, 1999
Messages
4,734
Reaction score
1
City, State
Celina, Texas
Year, Model & Trim Level
1996
Lookin Good.
 




Diff Whack Daddy

And the Roll Over Posse! Under the Hood Moderator
Elite Explorer
Moderator Emeritus
Joined
February 19, 1999
Messages
3,783
Reaction score
5
City, State
Mount Vernon, WA
Year, Model & Trim Level
1st Gen XLT 4dr
Callsign
KG7VTT
:popcorn:
 




zhanx

Explorer Addict
Joined
April 6, 2004
Messages
1,453
Reaction score
4
City, State
Up state NY
Year, Model & Trim Level
2000 xls
That frame is not clean enough!

This is a clean frame
2036219_86.jpg


Now get back under there and getter done!
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month "try out" option.

Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private conversations, and more. Join Today. Your support is greatly appreciated.




TarHeel085

And den
Joined
August 22, 2001
Messages
4,101
Reaction score
4
City, State
Raleigh, NC
Year, Model & Trim Level
'99 Sport 4wd
ill be the first one to admit, grinding all those brackets smooth SUCKS!! i have also discovered my rear drive shaft is to short, and that i will be building a custom trans cross member to compensate for the 3-link.

btw anyone know exactly how much longer a 4 door rear drive shaft is?
 




Top