My backyard build (56K warning)

[dude772]

To start this off, i want to say that spite is a fantastic modivator. If someone tells you that you cant do something or shouldn't, doesn't mean you can try.

So I started this about a year ago by taking the body off the frame. Which was easier teh second time after doing a body lift. The box was easy, lift it off by hand. The cab however was a little tricky. I used 4x4s between the cab and frame, used several combanations of jack stands and jacks to get it high enough to clear the engine. I ended up building a jackable stand out of a rim, angle iron, and a old bumper jack.

Then i left it alone cause this is canada and it gets cold and snowy in the winter. When spring came i got to work.

First I took out the rad support. I used and air chissel with a flat blade and broke all the spot welds. Took the old on out laid it on the floor, put the new one in lined it up best i could and welded everywhere i could. It took about an hour to do after countless hours of taking it off the frame and removing all the wireing... you get the idea.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00110.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00118.jpg

Next was the floor/firewall area. This is why i parked the truck, i developed a huge hole/crack in the firewall/floor seam.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00042.jpg

Using a cutoff wheel and a grinder i cut out all the rotten metal and replaced it with some 1/16th steel and angle iron to brace it even more. I did this a little at a time so that nothing would weaken anymore and sag.
http://i168.photobucket.com/albums/u193/dude772/Build/Beforewelding1.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00141.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00157.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00261.jpg

After that i did alot of work on the frame, taking off the engine/transmission, cutting off the old 2wd suspension, grinding it down, sanding and painting.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00320.jpg

Origonally for the 4x4 conversion i was going to use a stock setup and swap crossmembers. I even bought a parts explorer for this, but the guy i bought the explorer off of threw in a FREE dana 44 front axel. So now i had both options, so im now going with the dana 44 and i have to re-weld and bolt the origonal crossmember back on. oopsy.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00301.jpg

Durring the winter months i was in the garage at night cleaning the engine stripping it down and painting it when i could, its ready to go back together once i get a rebuild kit from summit.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00319.jpg

So thats where i have gotten to so far. Trying to figure out this dana 44 thing right now.

[samsonitesamsonite]

dang... looking good! keep us posted!

[hairyboxnoogle]

To start this off, i want to say that spite is a fantastic modivator. If someone tells you that you cant do something or shouldn't, doesn't mean you can try.


I definitly know what you mean!:icon_rofl:

[PARKINGLOT]

dang man, nice build so far...next time I'm down that way I'll have to stop by and check it out!

[dude772]

I definitly know what you mean!:icon_rofl:

"Its too far gone, you cant do it." "thats not going to work."

I showed them whats what!

[hairyboxnoogle]

Yeah!! Oh "its just a pile of shit, just pull the plates off it and leave it in a ditch", or "hey ill even haul it off for you" best yet, my dad offered me wheels and tires for my 77 if i got rid of my ranger..... i was like WTF!?!?!? Kiss my ass

[ChrisR1S]

Man thats awesome. Looking at your sig, what are your plans for the interior?

[wahlstrom1]

If thats a fullwidth D44, which it looks like, extend the radius arms 14", than build a new radius arm crossmember and use some flat bar to move your coil mounts farther in....It's pretty damn easy with our ttb trucks....

-andrew

[dude772]

Yea its a D44, but I want to narrow it bout 6" to get it back to about the stock width.

I know that i SHOULD leave it the way it is to compensate the high centre of gravity, but i really dont like the look of a full width on a ranger, way too much wheel stickout.

I have the axle damn near ready to start cutting, but i need theres a lil bit of info i need. I was told on the old forum that if i cut 6" off of the (drivers or passengers side) of the axle that it would be a stock replacement axel shaft from something else for if it ever breaks. I need to know what that vehicle it is that would have that length of axle shaft? And if im corrent on the 6".

I need an answer soon before i get impatent and start cutting. hahaha I want this to be driveable by the time winter rolls around. And once i get the front axle on, i can get the egine in there and put the cab back on. So its really holdin up my project here. hahaha

And the custom interior im not 100% on, i know im doing 86 cougar buckets redone from grey cloth to black leather with some blue in there somewhere, and everything redone in black, maybe some custom made door panels wraped in black leather and some blue suede? If it will fit, i wouldn't mind putting a newer dah in there with a larger radio hole, for an in dash monitor, and a possible onboard computer and gps?, just because that would be cool as hell expecially if i get lost in the bush. and of course a big thumpin stereo.

[PARKINGLOT]

get lost in the bush....around caledonia? damn...it's been forever since I've been out that way...is there good stuff? last place I was at was oshweken...

[dude772]

lol ive never been around here only up around pembroke, altho... today i did take my sunfire threw a farmers field around the outside of the corn stalks... looked like there was a trail leading into the bush.

But there are guys around here who somehow get their jeeps COVERED top to bottom in mud:dunno:

I dont know where the hell they are going but im definitly jelous that im not invited!

[PARKINGLOT]

ever heard of www.jeepkings.ca ? It's a mostly ontario based site, mostly jeeps, as the name implies, but there and ford guys, zook guys, etc, on there too...they know alot of places in S.W. ontario area...

[wahlstrom1]

I don't know exactly what length, but check either early bronco or wagoneer axle length, wagoneer being 2-3 inches wider then stock, but narrower than fullwidth.

-andrew

[dude772]

ever heard of www.jeepkings.ca ? It's a mostly ontario based site, mostly jeeps, as the name implies, but there and ford guys, zook guys, etc, on there too...they know alot of places in S.W. ontario area...


Yea apparently the guy i bought the explorer off of knows the owner of the site:S crazy... when im done the ranger i might roll over to the site and check em out, find out where they are going.

[dude772]

*UPDATE*

Workin on the dana 44 today an yesterday.

Its hard to cut the weld holding the end of the tube without cutting too much, takes a lil while. I was 1 grinder cutoff wheel width away the first time.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00370.jpg

I tried to take the hub and the rotor and all the stuff off the end of the axle and decided it was too much like work after getting the ball-joint nut off.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00372.jpg

Now ive come to a point where i need to ask myself .... how am i going to line it all up again.

I've got it all figured out for the end of the axle, but how in the world will i do the other 2 pieces that line up the radius arm:icon_confused:.

Well if it stops raining i'll get back to it.

P.S.
Who sells aftermarket radius arms?

[badblue]

i got james duff ones

[dude772]

Project got kicked onto the back burner for the past week and a half or so, found a buyer for my 2000 sunfire GT.
Which actually was a top priority to the build, makes for a higher budget which is currently zero dollars. So hopefully this guy comes threw with the $2500 in the morning, and i can order up the engine and transmission rebuild kit, and all the conversion stuff and maybe some new gears or some radius arms then with the rest pay off the visa that i maxed out. Im pretty excited to be able to dump some money into my truck :D

[dude772]

SUNFIRES SOLD!!! time to go and blow all my money on the ranger:D:D:yahoo::yahoo:

Im thinking....
- Engine rebuild kit
- 302 Adapter stuff
- Dana 44 gears and rebuild kit
- Primer and paint
- And a new box

Cant wait :D

[PARKINGLOT]

good stuff!

[dude772]

I am now summitracing.com's newest customer!
-86 cougar 302 rebuild kit(with METRIC piston rings!had alot of trouble getting the right kit)
-Advance adapters oilfilter relocation kit
-Ford Racing chrome valve covers
Grand total of $375.00

Also in the past few days I've cleaned the gease and dust from the engine bay and painted it up nice and pretty with some really nice bedliner paint and semi-gloss tremclad.
I'll take pictures later tonight or tomorrow its pretty good looking. You wouldn't notice I welded in over 2square feet of steel plate all over the place.

Next thing to do is build the engine back up, get some motor mounts, weld the cracks in my headers, weld in a few pieces of angle iron to the interior of the cab to close everything up then I could drop the body back on the frame then go to town on the dana 44....

or maybe i will do it the other way around? .... i'll figure it out... Can't wait for my parts to be here tho

[PARKINGLOT]

sounds good, keep us updated!

[THE WHITE RHINO]

do extended arms for sure with a flex joint(heim, johnnyjoint) on the end i like the fullwidth look

http://i41.photobucket.com/albums/e258/mikes1988pos/100_2982.jpg

[dude772]

[QUOTE=THE WHITE RHINO;27360]do extended arms for sure with a flex joint(heim, johnnyjoint) on the end i like the fullwidth look
QUOTE]

I cant do the fullwidth, this isn't going to be a pure offroad truck, and im pretty sure in ontario you cant have open wheels.

Not only that, im not a big fan of the full width look. I know its better for stability and everything but i dont like it... sorry.

Im going to niagara falls tomorrow to pick up my order from the mail box(cause its really expensive to ship it to my house from the states). And as soon as i get home, im going to go to town on the engine!!! next is cut down the dana 44, and get that in there and roll the frame back under the body and go to town on the wireing.

.... shit that sounds like alot :P lol we will see how things go.

[PARKINGLOT]

I cant do the fullwidth, this isn't going to be a pure offroad truck, and im pretty sure in ontario you cant have open wheels.


I don't know about that....I think you'd just need some kind of flares is all....

[dude772]

I don't know about that....I think you'd just need some kind of flares is all....

Yea i thought about that... but those would be HUGE flares.... when it comes down to it... thats really just not the way i want to go with my truck...



ANYWAY.... as i promised i took pictures of the firewall after I made it look all sexy with the bedliner paint...


http://i168.photobucket.com/albums/u193/dude772/Build/DSC00397.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00398.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00396.jpg

Compared to before paint ...

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00261.jpg

Why cant they just do this to cars from factory!!!??? they would last a million years longer!!

Getting closer... and tomorrow i get my engine stuff!!:yahoo:

[dude772]

And heres the parts fresh from summitracing.com!!!
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00399.jpg

[danger88ranger]

Looking good, cant wait to see it done

[dude772]

:mad::mad: I lost my damn head bolts!!!!! ARGH!!!!! That kindda brought the rebuild to a screeching hault.

All I got done last night was main bearings, rod bearings, piston rings and oil pump and pick up tube. Cleaned up one head went to put it on and couldn't find the head bolts for the life of me... so i put in 1 generic bolt for now to hold it there.

So now I'm going to go over to the junkers to snag a set for $5 after my job interview at the ford dealer :D

Now im thinkin bout doing a 5.0L explorer intake.... any thoughts?

[PARKINGLOT]

So now I'm going to go over to the junkers to snag a set for $5 after my job interview at the ford dealer :D


Winegard, right? It's right across the side-street from the chevy dealer, IIRC. I've delivered there a few times before.

[metalmacguyver]

why not get the head bolts while your at the dealership?

[dude772]

why not get the head bolts while your at the dealership?

Cause im cheap... and they dont have em. BUT.... I went to the scrap yard and found a complete 5.0L HO MAF motor in a thunderbird that i can have for $100, so i asked if i can take the wireing and everything attached with the motor and he says "however you wanna take it out go ahead". So then I get the HO cam, the heads(are they different for a ho? i dont think they are but not sure?) and the MAF wiring i wanted and the computer for $100.

I could get new headbolts for $60, or a whole engine and other parts i want for $100 and bring the block and other metal in for scrap and get up to $40 back. So I think this is going to be the better route. Rather than using the wireing harnesses i have and modifying them to accept a MAF, and then on top of that have to go out and get the computer anyway.

This way i also get spare sensors, and alternator, compressor, water pump, all kinds of good stuff i could use.

[metalmacguyver]

Damn! sometimes convenience is not worth the price.

[PARKINGLOT]

hey, if your just going to take the block back for scrap, if it's any good, I'll take it off your hands...

[dude772]

hey, if your just going to take the block back for scrap, if it's any good, I'll take it off your hands...

come give me $40 for it and you've got a deal. This engines even more worth buying now. Got under the car to unbolt the transmission and starter and that kindda stuff and what do ya know...
the oil pans brand new on it! That saves me $80 on the oil pan that i previously had to buy cause the old one was rotten to hell.

So looks like 2 days worth of work pulling an engine paid off HUGE!!

Im bringing it home tomorrow, and going to pull it apart. And its going to be a refresh course on what bolts go where. hahaha.


If anyone in the area needs a complete 4.0L motor that was 100% when i pulled it, its theirs for $200

[dude772]

Double... site froze on me...

[PARKINGLOT]

double post! yea man, by all mean's I'll take the block off your hands (it'll just be like, block, crank, rod's, and pistons, right? you took the intake and heads and stuff?). I could use a winter project like building a short block. Something for me and the old man to do together.

So it's an H.O motor out of a T-bird? do you know what condition the motor is in? (i.e, do you think it was running when taken to the j/y?)

[dude772]

double post! yea man, by all mean's I'll take the block off your hands (it'll just be like, block, crank, rod's, and pistons, right? you took the intake and heads and stuff?). I could use a winter project like building a short block. Something for me and the old man to do together.

So it's an H.O motor out of a T-bird? do you know what condition the motor is in? (i.e, do you think it was running when taken to the j/y?)

The only thing I know about the engine is that it turned over when i took out the flyweel to torque converter bolts. I can tell you more once i get it home and torn apart. But yea its an HO from a t-bird, im checking the year of it and everything tomorrow when i pick it up.

And yea it would be nothing but block, rods, pistons and crank. no covers no heads no accessories nothing but a starting point.

And you dont get to check out my truck :P haha. its at my buddies place in the shop/ barn conversion.

[PARKINGLOT]

that's cool...for $40 bucks, it's more than a starting point. Give me something to do over the winter. You keeping an EFI setup for your truck or going with a carb'd setup?

[dude772]

that's cool...for $40 bucks, it's more than a starting point. Give me something to do over the winter. You keeping an EFI setup for your truck or going with a carb'd setup?


EFI all the way! To hell with carbs!! haha yea carbs will do the job, but I like efi, yea its more thinking and wireing and all that crap, but i like it.

[PARKINGLOT]

are you just building a stock motor, or are you going to mod it a bit? are you using the stock, uh...whatever computer for the engine?

[dude772]

are you just building a stock motor, or are you going to mod it a bit? are you using the stock, uh...whatever computer for the engine?

Right now im interested in putting it in as stock... i REALLY miss driving my truck and i just want to drive it... then i will look into doing some performance stuff to it once its in there... like maybe an explorer intake with some trick flow heads. I dunno. I'll do something sooner or later.

[dude772]

Made some progress on the engine the past few days, decided to take some pictures.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00400.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00406.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00405.jpg
mmmm shiney :D


I think I am going to take the intake to get glass beaded so it's nice and pretty lookin, then spray it with some clear coat stuff for wheels that I've got. I cant have nice new shiney valve covers next to a nasty corroded intake... NO WAY! hehe. Once I get that done its just a matter of putting it on and then i can start hookin up sensors and wires and looking forward to mounting it on the frame.

hummmm.... on second thought... i better not look forward to it. If I really want to do it, I will do it WAY before im ready to put the body back on the frame and it will sit outside in the cold weather covered up very poorly and get rained on and have animals hide nuts in it... yea maybe I wont look forward to mounting it... haha.

Once the engines all done up, the dana 44 is my next victim!! LOOK OUT DANA! I'm gonna cut you up!

And, got bored so plaied with the explorer a little....

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00381.jpg

F YOU FIERO!!!!
it was going in for scrap and I had nothing better to do.

[dude772]

Small update that took alot of work.

Engine wire harness recovered with new tape and plastic loom.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00412.jpg
(oil pressure sensor wire in the centre pocket!)

And cleaned the hell out of the lower intake, injectors, distributor, fuel rail, and shined the valve covers. Couldn't put the distributor on yet tho, I've misplaced the oil pump drive shaft.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00413.jpg

Next for the engine, is a 1" intake spacer to clear the valve covers. And a shiney upper intake, oil pan, and the distributor. Looin good so far. I'm hoping to get around to doing the front axle this weekend. As long as the brake lines on a neon dont take forever.

[dude772]

Interior of the trucks coated in bedliner now... and so am I. Well I've got from under the windshield to the firewall/ floor seam done. Cause its cold and i only want to do as much as i have to.
I can put the truck together and drive it and finish the rest when I bring it to work so i can finish the rest in a heated garage.

Now I have to concentrate all my energy on the front axle. Couldn't do it today because i couldn't get any supplys for it, like stuff to make a template to weld everything back together the way it was.

Plus still trying to figure out how to build the radius arms and that type of crap. I was thinkin making some that bolt to the axle the same way as before, then have a leaf spring bushing on the other end. Seems to be a pretty secure way of doing it to me.

I guess there will be more to come next weekend.

But for now... im tired out!

[Sunk]

Man that engine is SHINY! Looking good though.

[dude772]

Man that engine is SHINY! Looking good though.

I think its mostly the way the light hits it.

[red85]

Looking really good so far. I've done a few V8 Ranger conversions and you're going about it the right way. A clean clear frame is nice to work with. Nothing in your way and no rust falling on your head! I'll have to check out your truck next time I'm up your way. There's a good wrecking yard close to you that I've been meaning to check out...

[dude772]

There's a good wrecking yard close to you that I've been meaning to check out...

.... Well dont keep it to yourself!!! where is it!? hahaha

Took some pictures of the little progress because i like to add lots of pictures, cause im the kind of person the just scrolls threw a build and looks at the pictures :D

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00417.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00416.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00418.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00415.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00414.jpg

P.S.
I'm aware theres still minor holes to be patched up, but I ran out of supplies tonight while I was trying to put on more bedliner on the firewall. So back to the parts store in the morning before work, then tune up on my brothers neon. Then back to work on the truck.

Also found a guy who will re-gear my axles free and show me how to do it :D i thought that was awesome. Its been rainy lately so I havn't been able to do anything with the frame or front axle. I'm very disapointed about that actually. Its basically the only thing holding me back now. Because after tomorrow (or the next time im able to work on the truck) I will be able to start putting the interior back together.

And i ordered my intake spacer kit last nite so that should be in soonish. Another 70$ into this money pit of a truck! lol

Anyway time for sleep. another busy day of oil changes ahead of me :bad: lol.

[dude772]

k, all the holes are repaired now. Cab is intact. All the welds have been covered with urethane, any overlaping metal has been sealed with urethane. Everythings been wire wheeled, primed and painted with truck bedliner then touched up with semi gloss tremclad.

This cab is ready for the frame!!!

Now I need to co-ordinate how im going to go about doing this. I need the frame under the cab in such a way that I can put the engine/transmission on the frame, then put the cab on the frame, then fabricate the front suspension.

.... this is going to be tricky moving the frame around without a front suspension after the engines on there....

Well time to start looking for a 4x4 AOD


oh and P.S.

If anyone cares to see... heres the rest of the firewall coated in bedliner...

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00419.jpg

[dude772]

ok... so a little bit of an update... Got the shop cleared out enough that i can squeeze the frame back in and under the cab. Took a hell of alot of cleaning and sorting and work but I got it there. That took the best part of the week. Then after that I tossed a pair of tires on the rear axle and knocked the axle stand out of the frozen ground with a big hammer.

After that, in the ice and snow me and my buddy Matt picked up the front end of the frame and carried it from its resting place to half way back to the shop. We only went half way because theres still the matter of his dads chevette in the way thats in the middle of getting brake lines. So hopefully tomorrow or tuesday, If all goes well i should be able to add a few pictures of the frame under the cab.

But ive still made zero progress on the dana 44, I'm procrastinating on that MAJORLY!!


Everything said and done... I think that I had a pretty productive weekend considering the temperature, the ice and snow.

[dude772]

K got out again today, had a half day at work so I did what anyone would do... worked on the truck in the ice and snow...

This is after we put some tires on the frame and moved it towards the shop

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00431.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00432.jpg

The cab as it sat before the frame was put back under.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00434.jpg

And later that night after it was wheeled under the cab

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00437.jpg

To get the frame in and under the cab we had to take those tires off and put bare rims on go at about a 45 degree angle to the cab, clear one stand then drag the ass end over and clear the next stand then straighten it out and put it back and line it all up. I just wish I could have taken a video of how goofy it was.

This weekend im going to repair the cab mounts on the frame they are getting pretty thin. This is assuming that we have more mig gas by then, apparently we are having troubles getting some:S. Then im going to put the 31s on the back again to get the frame closer to the cab. Probably will also put the tires on ramps or something. And just a really tall axle stand under the front. I'm getting pretty excited.:D

[Sunk]

Ooh sweet, progress!

[dude772]

tonight got the 31s on my 86 grand marquis rims to put on the back to get the frame up off the ground, the front i lifted up to the top of the axle stand. The frame is now approx a foot away from the body.

Found an AOD 4x4 transmission at the wreckers for $300 im going to pick up. And i will probably also get a rebuild kit for it because i dont really want to get a used transmission i know nothing at all about and slap it under my truck thats pretty much brand new. And i still need an electric shift transfer case.

And to make things easy on myself and the truck im going to try to make another pair of jackable highlift axle stands(upside down bumper jacks on home brew stands).

hoping to have the body on the frame by next wednesday? thats a goal, we will see how that goes.

[dude772]

Quick update... Cabs on the frame, the 3" body lift has been shaved down to a 2" lift. The interior floors been fully painted with the bedliner.

The engine crossmembers been re-welded to the frame(i cut it out and punched out the rivets when i was going to do a stock 4x4 conversion then changed my mind).

Things are coming together nicely. I will post pictures of my progress tomorrow, hopefully then i will have a mock-up engine sitting in the truck to check clearances and be able to fab up the headers.

Im still procrastinating on the dana 44... I'm unenthused about doing it cause that suckers heavy to unload from the explorer. But sooner or later it must get done. Im going to talk to the guys at bicknell racing products to see what they can do for me to help with the axle. As in making up some radius arms or re-splining the shafts.

[dude772]

Second update this week...

Found more holes just small ones i over-looked before cause i was rushing.... in the cowl on the drivers side, right in the corner. I took off the inspection plate and gobbed it up with fibreglass bondo, inside and out. If i missed that i would have been majorly pissed the first day it rained and i got my feet wet :mad:.

Got that all done and finished with, then i went to put the engine bay harness in... then thought to myself "self, youve spent countless hours making everything look nice and pretty and clean and tidey. Why the hell would you not clean up that nasty looking harness."

So i took the harness tossed it in the back of the explorer and called it a night at the shop. Went home and threw down an old blanket on the pool table and stared peeling back tape. So after christmas I've got to put the under hood harness in, fasten it down, pick up a 4x4 dash, and basically begin the "make it a truck again stage".

Heres pictures of this weeks progress...
P.S.
Sorry in advance for piss poor pictures... i keep taking them at night

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00444.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00442.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00446.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00447.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00448.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00450.jpg

[Black'03LevelII]

looks like it's coming together pretty good! keep up the good work man, the end result will be well worth it I'm sure. :icon_thumby:

[dude772]

Another little update.

Bought myself a new bed for the truck. best one i have seen in ontario, AND IT WAS AT THE WRECKERS!!:mad: the truck it came off had 174 000 km on it... damn thing was in better shape than mine! i dont know why people junk some of the cars i see.

Any way, picked it up for $125 and carted it home on the back of the f-150 upside down and on 2x4s strapped down to bed hooks in the 150.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00453.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00455.jpg
Thats my buddys dad in the back being a clown.

[dude772]

update:
Thursday I dropped the mock-up block into the truck... not so easy to do with one person and no engine crane availibe. But i managed with a little grunt work. The motor mounts i used were the stock 4.0L rubber mounts with the dowls ground off. The brackets on the engine were the stock brackets from a 93 thunderbird. The right side lined up without any trouble at all.

The left side i had to slot the hole in the bracket because the stud i the rubber mount was not in the right spot. I just slotted the hole last night at work, so today im going to see how well its all going to line up. Then comes putting on the heads and finding out what headers are going to work. The options ive got to work with are the MustangII 302 headers, and the 93 thunderbird H.O stcck headers. Either one I use i can modify to make it work, i didn't buy either, so i wont feel bad if i need to cut or bend them a little. But so far everythings going just nicely.

The only prblems i see with the motor mounts is that the engine is located a little too far foward, im probably going to end up making a couple plates to move it back a bit. We will see how things go.

[PARKINGLOT]

that's sweet box for ontario. Looking good man!

[dude772]

ok... so the motor mounts worked perfectly!... and i was right, the engines located too far forward. So im making up templates for plates to set the engine back as far as possible. Im using quarter inch plate, if that proves not strong enough, ive also got some half inch(or more) stuff i can use, im kindda against using that cause it seems too thick for the stud on the mount to even go threw...

[dude772]

ok, so today all i got done was situating the engine into a position that i liked... About a half inch from the firewall on the drivers side, and about an inch and a half from the firewall on the passengers side(measurements taken from the top of the head on the outter most edge).

Tomorrow im going to check the front brackets and pulleys clearance.

http://i168.photobucket.com/albums/u193/dude772/DSC00458.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00457.jpg

[dude772]

k, this weekend i got the engine mounted in the truck 100% the way i want it. I did end up bashing in the firewall above the drivers side cylider head for valve cover clearance. The 1969- 1986 f-150 mounts were PERFECT. They were nice low profile type mounts. The engine sat as far down as far as possible, any lower and i would need to do some major pan modifications.

heres a picture of the mount
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00460.jpg

and i also made a header for the passengers side... obviously its not built to perform, just built to get the exhaust from the engine to the back of the truck.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00466.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00462.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00463.jpg
Obviously its only tacked together and needs to be completed and more little bits added to it, expecially on number 1

and on the drivers side ive got a header designed for a mustangII with the 302.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00467.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00468.jpg

[dude772]

im bored so im gonna post up pics of what i did today and yesterday. I worked on the dana 44.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00474.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00473.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00471.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00470.jpg

So much for those in the summer that thought that my 44 had cast ends...

[dude772]

My good engine is now in the truck. Had to put a spacer on the drivers side between the mount and the block some clearance for the header and the steering shaft. Other than that, no problems at all.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00477.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00478.jpg

Now im thinking that the best idea for the transmissino will be to get the AOD adapter from advance adapters to use the RBV transfercase since i already have an AOD transmission thats 2wheel drive. The conversion would save me $300 from buying the 4wheel drive transmission and i would save more money by using the RBV transfercase, since i could pull that out of the explorer when im ready to drive the ranger then wait till i find one at a decent price.

[red85]

That thing is looking great! You're going to have to come down to Kitchener to check out some of the Rangers here. Tons of ideas for you...

[dude772]

That thing is looking great! You're going to have to come down to Kitchener to check out some of the Rangers here. Tons of ideas for you...

I was actually in that area on the 1st. I went to Cambridge to True Gear to drop off the passengers side axle shaft for the dana 44 for them to cut and spline. I called them today actually and didn't like the news i got. By the sounds of things they havn't even touched it since i dropped it off. So its going to be a week before i get that back.

Tomorrow im going to mess about with the wire harnesses. Hope to get this thing finished sometime soonish. haha

[dude772]

I've been having fun with lots of wires lately. I finally gave up listening to other people, and printed off the pin outs for the 4.0L computer and the T-Bird 5.0L computer, the diagram for the fuel pump and relay for each.

Once I started relying only on my print outs and other literature ive got and the wire harnesses infront of me, and a little help from looking at the harness thats in the explorer to see how they routed it from factory, i was good to go. So far ive got the harness for the TFI extended to mount on the rad support under the battery. The main relay power, ground, and keep alive power for the computer. the fuel pump wired up, with the inertia switch. Basically next ive got the gauges to do and the WOT a/c cut out relay and the other stuff to go along with that.

The major problem with the T-bird is that nothings located in the right places, all the power wires go to the wrong side. the MAF sensors on the wrong side, the tfi goes to the wrong side(for easy mounting at least).

anyway heres a pic of all the wires laied out mostly the way its going to be. and the paper on the engines the diagram i re-worked to help me wire up the engine. I did it on paper first with all the wire colours and stuff. easier too see it on paper then imagine it in your head.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00490.jpg

[dude772]

And 2 weeks after i started tearing into the wire harnesses its done!

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00501.jpg

Engines all wired up. Since that pic, ive installed the flywheel, torque converter, transmission, starter, battery cables, routed and hooked up new fuel line, installed some scrounged spark plugs and scrounged plug wires. Next ive got to get a new cap cause i cracked the old one while i was transporting all the parts in the back of the explorer.

Once i finish up with the plug wires and ground wires from engine to body and frame and dump some oil in it, im going to toss on a coil and hook up the dash to try and start it up!

WISH ME LUCK!

I tossed around the idea of cutting the engine cross member out completely and building custom brackets and a skid plate since im also doing a SAS. Any thoughts on that?

[red85]

Take a look at DT Starr's build. He cut his x member out too and it seems to work really well. He's pretty close to where you are. You may be able to get a look at what he's done and take a few measurements.

[dude772]

F*** haha. I went to try and see if the sucker would crank over after hooking up ground wires to the body and frame. All i get is the main relay clicking!!! what a bastard! Now i get to spend all damn day figuring out what it was that i did wrong tomorrow!

Cranks over jumping the starter relay, so that tells me the ground to the engines good, that the power wire to the starter is good and the switch wire to the starter is good.

Have I mentioned anywhere that i really hate wires!

[dude772]

ITS ALIVE!!!!

I finally got some gas into it, and found out that the cam that was in the HO wasn't actually an HO cam so it was misfiring caus the plug wires were set up for the HO firing order.

Once i switched em around she fired right up! then i taped the MAF sensor onto the intake so that it was sealed up nice and tight. Turn the key(or screwdriver in this case) and VA VA VA VAROOM!

I took a video on my phone, and will post it when i get home tonight. I'm just excited that i got it runing without a huge headache.

[dude772]

Heres the video! Im excited!

http://i168.photobucket.com/albums/u193/dude772/Build/th_MOV00003-0.jpg (http://s168.photobucket.com/albums/u193/dude772/Build/?action=view&current=MOV00003-0.flv)

[zainyD]]

That's a big step, congrats!

[dude772]

;91716']That's a big step, congrats!

If that was a big step, the wiring must have been an entire flight of stairs haha.

[dude772]

Got bored and decided to paint the dash. I kind of gave up trying to glue vynal to the dash around the passengers side near the middle. I can make it work everywhere but the big dip in the passengers side. So i pulled the dash from a parts explorer i bought cleaned it up really good and painted it today.

Before painting After cleaning
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00139.jpg

After painting
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00141-1.jpg

I wanted the paint to last as long as possible, so I used 2 spray cans of vynal paint on it and the glove box and the ashtray, i havn't gotten to the trim for the drivers side or the side vents yet.

[dude772]

Another little update, I've been playing with the dash harness and wiring in general. Ive put the electronic 4x4 switch wires in, the power window wires in, the power door lock wires in, and while I was in there I re-wired my remote start and alarm to look alot cleaner.

This truck origonally didn't have any power options, I put in aftermarket power window motors and door lock solenoids. I used wires from my parts explorer to use the factory circuit breaker location for the power windows, And for the 4x4 switch wires.

There was already a 4x4 power wire in the underhood harness and a rear defrost power wire. The defrost power wire will be used for the power door locks.

The remote start/ alarm has got a trunk pop button that I was thinkin about wireing up as a door popper or maybe some kind of remote window control.

EDIT: And a picture to go with my headache :P

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00146.jpg
Note the different harnesses on the pool table and floor, unpictured are 2 more hanging from the ceiling.

[MUDDING B-3000]

thats a sick build cant wait to see it all finished up

[dude772]

Working on the seats today. Not exactly what I had in mind but Its costing me very little.
Im also a little pissed too. I had seats that i saved for the Ranger from my moms 86 cougar(same car i got the origonal 5.0L from) they were really nice grey 60/40 split with a centre consol in the middle instead of a third seat where all my power option controls were going to go. Like my power windows, locks, lumbar, and any extra stuff i installed in the truck. The seats had a removeable headrest so they were looked like a low back seat. That was the biggest reason why i liked them. I had it all planned out perfectly to use these seats. Saved them for over 2 years. I stashed them in a dead tarus car at my buddys house and told EVERYONE that they were in there. I reminded people everytime they went into that car that im saving those seats and to not scrap the car unless the seats get pulled out.

Well last week guess what happens, of course they scrap the car. but they took the seats out at first and thought about why they were being saved in there. Then decided to cut the springs out of the bottom to make electical probs and tossed them back in the car and hauled it away to the scrappers. So even if i did go back to the wreckers to get them back out of the car they are destroyed.

So now I've got to use the seats from my parts explorer. Definitly not my first choice, but they will work.

I stopped by Fabricland and got some Dylon black fabric dye and went to town on the passengers side seat. Took the seat cover off of the frame and laid it out. Mixed the stuff as directed and used a cloth to rub it into the seat, went over it untill i ran out of mix. Then rinsed the cover untill the water staied clear, well mostfully clear. Enough that i would be confortable wearing a white shirt while sitting in the seat.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00512.jpg
Hard to tell that its been dyed, but it looks darker that the picture. It is still kind of grey, but all I was looking for was something that would be dark to match the rest of the black interior.

EDIT:
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00516.jpg
with the dirvers side cover next to it with the light not shining directly on it giving a glare.


Then I remember i saved the lumbar support from my younger brothers 93 crown vic when i scrapped it. So i grabbed the airbag from that and tossed it in there. Theres tabs cut into the frame for it already, all you need to do is trim the bag supports and a small section out of the bag. slide the supports threw the sides of the air bag and bend the tabs around them and route the air hose. The hose goes to the switch and theres another hose that goes to the motor. Finish off with mounting it all and supplying a power and ground. Easy!

If you were to try and install the lumbar in another truck, it could be done without removing the seat. It would probably take about an hour to do both sides.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00515.jpg
All the parts needed

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00514.jpg
Bag installed

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00513.jpg
Everything hooked up, tried it out with the battery and works perfectly and is VERY comfortable!

[Boggin-B-Series]

Lookin Good Man. Keep It Up

[dude772]

I did a full write up on how to do the power lumbar with lots of pictures when i did the drivers side seat.

http://www.therangerstation.com/forums/showthread.php?t=17280

[PARKINGLOT]

looking good man!

[dude772]

Im falling behind on this thing.

Now I've verified that the 4x4 switch works, i hooked up the transfercase to test the switch and the transfercase to make sure they both work. And yesterday I picked up some springs for the front. So soon enough it will be sitting on 4 wheels for the first time in .... i cant remember how long.

The springs I ordered are the classic bronco 5.5" lift springs. Im going to modify my stock spring perches to make them work. The springs are really tall, haha. I didn't get around to taking a pic of them yet. I will get one when I start fabricating something for the suspension. Possibly take a pic of them next to the stock springs to compare.

Im really excited to get the front suspension all set up!

Hopefully I can get a bunch of it done on my day off this friday. I dont get to work on the truck alot anymore now that im working full time again. But it does give me lots of money to be able to buy things for it.

[dude772]

Another update.

No pictures again because I keep foretting my memory card reader at work in my toolbox.

I've got the axle under the truck, I've decided to go with a 3 link system. Ive gotten the brackets for the lower links all cut out with the torch and ready to clean up on the grinder.
Ive made the passengers side link. I accedently made it too long, but I'm going to use it anyway, because its too much hasstle to shorten it. The passengers side is all setup with the spring in the modified stock spring tower and on the bracket for the axle. I used 3/8" plate for the brackets and 1/2" plate for the spring retainers.

I also put some ball joints in the axle and put everthing together with tires to see how it all looks and if the axle is located where it needs to be. Everything is coming together very nicely. As soon as I get my card reader there will be pictures to post.

[dude772]

New springs compared to the origonal '77 radius arm

http://i168.photobucket.com/albums/u193/dude772/DSC00532.jpg


New spring compared to the old ranger springs

http://i168.photobucket.com/albums/u193/dude772/DSC00533.jpg



My modified spring tower, the "D" shape is the spring retainer, there will also be a piece that clamps it into the tower.

http://i168.photobucket.com/albums/u193/dude772/DSC00534.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00535.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00536.jpg


Trial fit of the springs with the '77 radius arm. This ended in me getting a heavy ass spring in the forehead... do not try this!

http://i168.photobucket.com/albums/u193/dude772/DSC00538.jpg



Shortened axle shaft. This was the biggest bullshit ever! sent it out 4 times because they kept screwing it up! Ended with them pissing me off and taking it to my friend who had a lathe.

http://i168.photobucket.com/albums/u193/dude772/DSC00541.jpg



Axle under the truck...

http://i168.photobucket.com/albums/u193/dude772/DSC00543.jpg



The end of the link that I made.

http://i168.photobucket.com/albums/u193/dude772/DSC00544.jpg



Finally... the axle under the truck with the tires on for a trial fit. The axle stands are not supporting the frame, the front ones are only making sure it doesn't go side to side. The rims are from a 92 F-150 I scrapped, and the tires are 31". They look big on the stock explorer, but tiny on the ranger!

http://i168.photobucket.com/albums/u193/dude772/DSC00545.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00547.jpg

[Carlos Murphy]

Keep the pics comin, I just love a fresh, revived block ready to be stuffed with all new and shinny parts...:woot:

[dude772]

Had a problem with where I mounted the links. They were too far towards the outside of the axle, when I accedently moved the tire i noticed that it hit the link that was just sitting in place. So I cut them off and relocated them.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00564.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00565.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00566.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00567.jpg


You can see in the second picture where the wedge used to be. Im more toward the center of the axle compared to that. So I should be good for some 35" tires with enough clearance. I do still need to ad another brace under the spring bracket. I'm not very comfortable with it hanging out so far with no support on the end of it.

The third link tabs and the trac bar tabs need to be made still.

[dude772]

Some news for today.

I ordered some headers from james duff today, and i ordered the transmission adapter kit to adapt the AOD to the ranger transfercase. I made arrangements for the transmission guy at work to build it for me and I'm waiting to find out about some front accessory brackets from a 5.0L explorer.

Going to pick-up the headers and adapter on monday. Trans should be ready for the following weekend.

It feels like im getting down to the final stages of the build. I'm Pretty excited.

[dude772]

Made up the frame brackets for the links today. 3/8" plate, I think that should be big enough. haha.

Got them cut and welded today. Excpet i was paranoid about melting the bushings in the rod end, and paranoid about the steel plates warping a little bit. I took the rod end out and hoped for the best.... well i failed. The plates warped a little and now i need to bend them slightly to fix them.


http://i168.photobucket.com/albums/u193/dude772/DSC00568.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00569.jpg

http://i168.photobucket.com/albums/u193/dude772/DSC00570.jpg

[dude772]

A truck load of stuff for the ranger today. I went and picked up my transmission adapter that i got from advace adapters, and my headers that came from james duff.

Then when I got back I happened to be at the right place at the right time and picked up some 35x12.5R15 tires and rims to go with them that just happend to have a 5x5.5 bolt pattern to fit on my dana 44 front axle and I will have some way of adapting them to go on the rear axle too.

The rims cost me $100 for all 4, and the tires were going to be thrown away so they were free. the tires are brand new and still have the painted lines i the tread and little noobs on them.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00572.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00573.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00574.jpg

And earlier this week i also picked up the front engine accessory brackets for a 97 5.0L explorer.

[dude772]

And my new rims and tires mounted on the front of the truck. Looks much better with 35s now!

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00576.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00577.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00578.jpg

[compleckz]

sweet

[KELLY88]

Truck is looking sick! One question: how are you going to get it out of the garage when you're done?

[dude772]

Truck is looking sick! One question: how are you going to get it out of the garage when you're done?

Hahaha yea theres alot of CRAP around it. The garage isn't actually a garage, its a barn converted to a shop, so the doors not the problem. All I will have to do is crank the steering pull forward crank it the other way back up and then pull out.

Or i could break down and clean the crap. But I dont see that happening.

[dude772]

Transmission time!

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00581.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00582.jpg

Took it all apart put the new 4x4 adapter output shaft in, going to order up some parts for it tomorrow to make sure the transmissions going to be tough enough. Should be ready to go by thursday and back in the truck this weekend.

I've got the transmission guy at work helpin me out.

[odie1969]

what are your front jack stands made out of. it almost looks like thos old jacks you would find in the dodges from the 70s welded to a steel wheel. Just wandering thanks

[dude772]

Close! there old chevy bumper jacks flipped upsidedown and welded to steel wheels with angle iron. They work perfectly, cause theres no other way i could easily jack something like this truck up and down as needed.

[turbo cat]

poor poor little fiero:sad: looks great man how much $$$ do you have in the 302 swap?

[dude772]

poor poor little fiero:sad: looks great man how much $$$ do you have in the 302 swap?

$90 in mounts
$300 for headers
$100 for a core engine and all the wires and computer to go with it
$300 for a rebuild kit
$200 for 97 explorer front accessories and p/s pump
$70 valve covers
$110 intake spacer
$70 oil filter adapter
$100 for misc wires and shrink tube and solder
$100 for a starter
$500 for the transmission adapter

The transmission cost me nothing to save when i scrapped another car but will cost me to rebuild
countless hours rebuilding the engine, and wiring it up

So it was about $2000 so far that i can think of off the top of my head.

and of that i recovered $60 selling my origonal 4.0L and the wire harness from a scrap explorer.

[fellows86]

awsome build man . Glad to see some more ford guys around this area . seems toi be everywhere you looks its chev fullsize and s-10s . keep up the good work

[lil red]

nice build, now all you need to do is come here and do the same to my truck:)

[dude772]

nice build, now all you need to do is come here and do the same to my truck:)

Sure no problem. As long as you can afford the hourly rate :P haha.

Got the transmission all buttoned back up today. Had a problem with the parts supplier not sending one of the drums. So we had to wait another day to get it.

Its all good now tho, new seals and gaskets, direct drum, new clutches, new pan, new band, and a shift kit. I wanted this transmission to last a little bit longer than the A4LD did hahaha.


http://i168.photobucket.com/albums/u193/dude772/Build/DSC00584.jpg

There she is next to the truck, I'm going to toss it back in the truck tomorrow and hook up some cooler lines and bolt the headers in then I can figure out where to mount my third link so its not in the way of the exhaust.:icon_thumby:. Should be fun.

[dude772]

And from sitting next to the truck to being bolted up under the truck in 1 day :D. Got the transfercase in also.

The transmission belhousing had to be modified slightly to make things fit properly with the headers. There was a tab just above the starter and a tab at one of the belhousing bolt on the other side. had to grind those off and then it slipped in no problem!


I think i have to tweek the headers that i got tho. they dont seem to fit just right.... nothing a nice long pry par cant handle!

Also bought a bunch of grade 8 bolts for the suspension today... The bolts i got for the suspension joint i got didn't have enough threads on the end, so they need to go back and get exhanged for some slightly shorter bolts or some with more threads.

[dude772]

I've posted these in other threads on the site, but they belong in here with the rest of my build so here are my shots of the transmission installed, and the headers installed.

There are a few clearance issues with the headers to the transmission, and headers to the front axle.


http://i168.photobucket.com/albums/u193/dude772/Build/DSC00589.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00591.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00593.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00594.jpg


Im really not impressed with the James duff headers. Definitly not suggested!

[dude772]

BAH!!!!!! F**** One damn problem after another! First the steering shaft is found to be no good cause theres a mile of slop in it. Then the headers dont fit corectly. Then the crank is the wrong size, then the water pump pulley isn't correct. Then the water pump is incorrect. Then the tentioner doesn't come with the bolts. Then the starter goes for a shit again. Then there a wasted day at work. Then I have to renew my plates. Then I have no money to get lift leaf springs cause i need to buy all kinds of new front engine stuff. BAH!!!! I just want to fill the damn thing with coolant and run it for more than 5 seconds.

SO! hopefully the Mustang II header for the drivers side that i origonally had will fit a little bit better than that P.O.S james duff header. If not im going to have to break down and buy the advance adapters headers. Then I've got to get bushings for the trac bar and make some brackets for it, make the third link(STILL). Some bull crap with the front accessories. Then maybe i can make it move under its own power... but only a little bit, just to make me feel better about this whole thing.


I had to get that out of my system!

[dude772]

more to add.

Finished the heat/ac box didn't like the thought of using sheet metal or duct work to modify the box to work. So i used cheese cloth and fibreglass. But i was in a hurry to just get it the hell done so i didn't bother to make it 100% smooth. I took out the high spots and made it more than good enough for what i want.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00599.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00601.jpg

Then i farted around with the intake. I wanted to try and re-use the intake that i made for the 4.0L. I dont like it the way it is and i will do it again once everything else under the hood is done. But for now it will work. I want it to come accross the engine bay and over to the wheel well. Much like a mirror image of the stock setup.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00602.jpg

I also ordered the 4" lift drop pitman arm and 6" lift leaf springs from National 4WD. They got the parts in over night. Went to pick them up on tuesday. The springs were picked off the shelf in the warehouse wrong. The tag on the springs were the correct part number, but the part number on the springs were wrong. So i re-ordered those but it was after 5 so it was ordered the next day to come in today. But they never showed up.

So even something as simple as bolt in lift leaf springs get screwed up for me :D haha.

In the meantime ive been removing the stock leaf springs. And the torch has been the tool of choice so far. Well.... the torch and water filled fire extingusher, since the bushings dont get along with the torch haha.

[dude772]

got the lift leaf springs in today. :D.

kind of a pain in the ass. All of the bushing sleeves were seized. I had to grind and cut the springs at the ends, then grind the bolts with a thin grinder wheel between the spring bushing and the spring mount in the front. Then in the rear of the spring i cut the shackle in half on the outside and air cheseled the inside that was rotten and about to break. After that i did the same thin grinder wheel on the shackle bushing bolt on the inside of the mount.

After everything said and done didn't take too long, but i got dirty as all hell! Im not a huge fan of where the rear axle is positioned. I would like it about 3/4" to 1" toward the rear. I will probably put in a lift block that will have offset holes to make up for the spring location.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00604.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00603.jpg

I still have to modify the explorer rear axle to go under the ranger. I will try and work on that on sunday. Then i need to decide how im going to adapt to the f-150 bolt pattern in the rear. I can use adapters, or i can modify the f-150 axle shafts to fit the explorer axle and put the backing plate and brakes from the f-150 axle on the explorer axle. I like the idea of the 150 shaft modified. We'll see how things go.

[Stumpy]

Awesome build!

I wouldn't even be able to touch the truck until I got that shop clean... I'm real OCD on that. lol it's bugging me sitting here!

[dude772]

Awesome build!

I wouldn't even be able to touch the truck until I got that shop clean... I'm real OCD on that. lol it's bugging me sitting here!

Yea it really gets to bug me too. But its not my shop to say how things should be. And I get to use it for free. I just freak out when things go missing or my stuff gets broken, like my cutting torch :pissedoff:.

The upside to some junk being around the truck is that its easier to get under the hood when you have a chevette engine to stand on. haha.

Damn rain was holding me up from what I wanted to start on today! I wanted to start cutting the leaf spring perches off of the explorer axle and prep it for the conversion. Oh well, it if doesn't let up tomorrow i guess im going to brave the rain and get it done!

All i did today was remount the battery tray. But slightly different from stock. I mounted it lower and more forward to clear the alternator. So today was the first time i could work and listen to the radio from the truck. Then i started to wrap the wires with self amalgamating tape to seal the wire harness then with the plastic protection stuff, and finally sealed with electrical tape. There shouldn't be any problems with the harness down the road.

[dude772]

Started on the rear axle FINALLY! haha. The first time i tried to start on it i had a huge headache with 1 lugnut. It was one of those chrome cap styles, so obviously it corroded and bulged, so i hammer on the 19mm socket, then the cap spins off and i hammer on an 18, it spins, then i hammer on a 17. Somehow that ends up spinning! So i magically hammer on a 16!!! and then the top of the lug nut breaks!!

So i got fed up and left it alone till a nice day like today came around, had to tear into it find out that its a limited slip diff :D(BONUS!) then smash one of the drums into 15 pieces to get it off. then take the axle shaft out, then smash the wheel into the axle with a seized drum take the C clip out. Then smash the wheel off with the axle shaft attached grind the head off of the stud and pound it and the half a lug nut off.

WOW lots of fun!

While i was in the rear axle mode, i tore into the F-150 rear axle i have too. That was way easier, the lug nute came off easy, no seized drums and only 1 broken diff cover bolt. Take the axle shafts out and get them all cleaned up and ready to be sent out to be resized to fit in the explorer axle so that i will have an axle that fits under the ranger nicely and still have the F-150 bolt pattern without needing any adapters, spacers, or making it look like a hack job. No offence to anyone who has drilled their axle shafts for the 5.5 bolt pattern!

[dude772]

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00609.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00611.jpg
Pictures after the front accessories were all finished up.


And what i did today.

I took the brake shoe assembly and backing plate off the explorer axle, and put on the assembly from the f150. Since im going to have the 5.5 bolt pattern i might as well have the drums and brakes to go with it. Makes everything look nice and normal looking.


http://i168.photobucket.com/albums/u193/dude772/Build/DSC00615.jpg
The explorer origonal setup.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00613.jpg
Removed from the f-150 axle.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00617.jpg
Compared

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00614.jpg
installed on one side

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00616.jpg
Compared again


Hopefully this week i will get time to bring the f-150 shafts in to be resized. Im going to give True Gear another chance to see if they can get something right. Seeings how they are the only place i am able to find that can do it.

I didn't get any pictures of it, but I took out the 2 piece 2wheel drive drive-shaft out. Measured up the length i needed and made up a 1 piece 4wheel drive shaft. Had some complications with the retainers breaking and busing the retainer lip and the ear of the shaft. So i ended up using a piece of the explorer drive shaft. It looks like its gonna work. If so i will get it balanced and use it. If not i'll get one from the wreckers or order a new one. at least i tried.

And im ordering up some spring perches for the axle, should be under the truck soon.

*EDIT*
Perches ordered
http://www.ruffstuffspecialties.com/catalog/d60-88-9-spring-perch-p-253.html
Found that thanx to the pictures on crawlin91's build thread. Thanx

[mjonesjr]

Nice job.

[dude772]

dropped off the axle shafts today. everything will hopefully be ready to roll next weekend. If all goes well.

[dude772]

Ok, axle shafts are going slow as hell! AGAIN! damn these guys take a long ass time! But unfortunately its the only place within a reasonable drive that can do it. :( oh well.

I've got my spring perches, the high misalignment adapters came in today, ive got the front pads and calipers, the rear brakes i can have at any time its all in stock. I finally found a place that has the shift shaft that i needed for the AOD. So thats going to be modified for the ranger tomorrow at work in my free time. Things are coming together just nicely now.

I cant wait to get my axle shafts in! then i can put the rear axle together and toss it under the truck and have all 4 35s on the truck and see how she sits. I'm considering taking my vacation time from work and just taking it to work my ass off on the ranger. I think im close enough and have enough parts that i can take a week and get it driveable.

CANT WAIT!!! haha.

Pictures to come.

[dude772]

Stuffs not going my way lately. Found out that im going to have a hell of a time with my axle shafts. But i am determined to do it this way!

I made the upper links. Used 3/4 hiems from bicknell racing products and misalignment adapters from ballistic. Got the hiems, DOM tube, jam nuts and weld in slugs from bicknell.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00618.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00619.jpg

I hate having to grind down perfect looking welds :icon_welder: :(. Oh well got to make it all look pretty!

They turned out really nice.


Then i decided to ream out the passengers side tie rod to accept a ranger outter tie rod end which will become the end of the drag link. I didn't want to ream it out because i wanted everything to be serviceable without modification. But this was easier. So i found a reamer that looked 60 years old in the shop and hadn't been used in 30 years. And i made it work! Its designed for an industrial drill press. but i needed it to work in a hand drill.

So i welded a bolt to the end of it and put a nut on that bolt and tack welded those together so i could use it in the inpact gun, seeings how that all i could find that wasn't broken.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00620.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00622.jpg

Worked out nicely. Got the tie rod in there nicely. i also ordered up 2 more 1985 4x4 chevy tierods. so i can cut the ends off to use the threaded ends to make a centre link between the outters. Cheaper than tryin to find a 7/8 - 14 R & L thread bolt or threaded. tie rods were $12 a piece.

I also made the shift linkage for the AOD. took the shaft that goes threw the case fo the AOD and put the lever from the A4LD on it. The levers are brazed to the shaft, so you need to heat the crap out of them, may want to put a notch in the lever first so it has somewhere to give when you heat it. then just pry it off. Then slide the A4LD lever on and tack weld it in 2 spots. Worked nicely.

I am considering taking a week off of work just to work on this pig so that i can get it mobile.

[dude772]

Welded the axle brackets on solid tonight. Tried to arc weld them, but i tried it while the axle was under the truck and it was pissing me off and i had ALOT of trouble gettin it to start. So i said F*** it! Brought it to my buddys shop and used his heavy duty mig welder.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00623.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00624.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00625.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00626.jpg
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00627.jpg

Now i have a few more brackets for the axle to make but before i could i had to get these ones welded up solid. Now i can get the upper links brackets made up, and the trac bar bracket welded up.

Im getting very frustrated with my rear axle shafts tho! They "SHOULD" be ready for thursday, but im not going to hold my breath. If they aren't ready, I'll Just order up some custom moser axles for $175 each.

[dude772]

axle shafts are back! going to get them in on thursday!!! YAY!

finally 4 wheels all the same bolt pattern and all the same design with all the same size tires for the first time in over 2 years!

[dude772]

Axle shafts are in. Worked out GREAT! everything fits nicely. I will take pictures soon. I ran into a little trouble tho. The axle tubes on the explorer axle are a larger diameter than the ranger. So i had to get new U-bolts for the explorer axle tube diameter(3.25").
Then i found that the spring perches i got have a locating pin hole diameter thats a little too small. i need to drill it out to fit. But the drum fits as it should and clears the backing plate, which was the only concern that i had.

While i was waiting impatiently for the machine shop to finish my axles, i found a cheaper way to have this done. Order NEW axles from MOSER. They will custom make new shafts with warrenty to the dimentions you need for $400 shipped to canada for both. I paid $500 for old shafts to be cut, welded around the diameter to oversize the diameter, machine to spec and re-spline and machine the button on. I've got no warrenty and i spent more. If i have a problem, i'll order moser axles.

I cant wait to get the rear axle bolted in and have my 35" tires bolted on front and rear! I am surprised that no one has done this type of rear axle yet. Well not that i have been able to find at least.

[dude772]

Ive got crappy pics to upload, it was dark and only had my phone as usual.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00638.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00639.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00642.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00641.jpg


and my new daily driver...

http://i168.photobucket.com/albums/u193/dude772/Explorer/DSC00629.jpg

Already put 18" rims with 07 f-150 sized tires on(32") Soon to get add-a-leafs and torsion twist.

[dude772]

nice weather is here now. So its time to get my ass out to work on my ranger again. Since last time, not alot of change.

Ive gotten the factory 4x4 lift blocks and installed had to get custom made u-bolts that were 11 inches long, the 4x4 trans cross member,(i accedently scrapped the last one with the parts truck, oops!) the front driveshaft is installed, the steering has started to come together with the center link fabricated and installed and the rest to come soon. The trac bar and torsional links are also now in and the axle stands have been removed from the truck.

i bought some flush mount valve stems threw work. They are made by "gorilla". They looked like the perfect idea for the ranger so that valve stems dont get torn off in the bush leaving me with flat tires. The biggest things that i have to do next is fab up a shift cable bracket at the transmission, something to hold the front springs in on the axle, and find and fit shocks all around.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00689.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00691.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00692.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00693.jpg

The links are not tight and are twisted right now, thats not how they will sit in the end, its just how it is now.

[Rinny650]

Dude does your licence plate seriously have 007 for the beginning? Sweet!

[fellows86]

WOW been awhile since i seen any updates on this thing glad to see your gettin back at it cant wait to see it done

[dude772]

hahah no, its 857. If i got my plate for the new explorer earlier in the day it would have been "007 BERN" but I got it at the end of the day and got 077

[dude772]

WOW been awhile since i seen any updates on this thing glad to see your gettin back at it cant wait to see it done

Speaking of which, what headers did you end up using for yours, I need to order some new ones, the james duff headers are garbage as far as fit and finish. Im thinking the AA 4x4 headers might work.

[fellows86]

Speaking of which, what headers did you end up using for yours, I need to order some new ones, the james duff headers are garbage as far as fit and finish. Im thinking the AA 4x4 headers might work.

i ended up gettin a set of mac long tubes for a 5.0l mustang . then me and my friend did lots of cuttinand welding but turned out great in the end

[fordwheelinman]

The james duff headers prolly are not designed to be used in a solid axle swap application.... i dont know, just throwing something out there.....

[dude772]

The james duff headers prolly are not designed to be used in a solid axle swap application.... i dont know, just throwing something out there.....

Its not just the interferance for the pinion, i can accept that as a "this wasn't designed for this type of application" type of deal. But the other side(passengers side) points directly to the trans crossmember, and tries to go under the transmission to cross over to the drivers side. Its a terrible fit! i dont like it at all one bit.

And the fact that they would not reply to any of my emails, and when i tried to call and talk to someone i got dismissed. I gave up. When the time comes to finish that bit up im going to order the AA headers. Most likely the 4x4 headers.

Today i had a bad day at work, so i had to go and work on the ranger to let off some frustration. Got the trans crossmember fitted, lined up the frame re-drilled for the new position and bolted in with left-over grade 8 1/2" bolts from the axle swap. tried to figure out what position i want to have the shift lever on the transmission, if i put it too low it will interfere with the front drive shaft. seems like an easy thing to make work.

The aim recently is to have this thing ready by the end of the month. I take a week of holidays at the end of june to work away at the truck. I want to take it up to Pembroke on the logging trails when i go in august. I'm gettin pumped to drive this thing for the first time in 3 years! Its brutal having all this time, energy and money sunk into a pile of metal sitting in a barn shop.

[dude772]

I've got this week off of work. And the only thing ive got planned is to get this beast DONE. Got a bunch of stuff done today. Front and rear brakes installed. The fronts were very frustrating because the axle didn't have brakes on it when i bought it. So i had to figure out the stupid spring, holder and anti rattle clip design. But i won in the end.
Rear brakes went nice and smoothly. New shoes, spring kit, wheel cylinders, and drums. Yesterday i went down to have some braided stainless lines made up. Those were finished today. I had the rear extended 13 inches and the front line i had made to be 25 inches total. I only had the end bit still bolted to the axle, so i had to guess at what i needed. $110 out the door for those.
Yesterday i also finished welding the front axle together. All the brackets and tabs for the links and trac bar.
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00696.jpg

Tomorrows plan is to finish running brake lines and bleed the system. Then if things go well I can fab up the shift cable bracket, so that i can weld the shift lever on the transmission then fill the trans with oil. After that its just a matter of the steering before it will move under its own power. Then theres still other things like gears, hubs glass and interior stuff. But the main goal this week is to make it move from its 3 year old ruts.

[dude772]

An update for today, no pictures. Ive been workin away too much to take pictures of anything. Couldn't find the origonal shift cable bracket at the transmission, i know i have at least 2 of them, but i cant find them. So i fabricated one out of some steel i got with the brake hoses. Then i was able to modify the shift lever that goes into the transmission. once that was done i could fill the transmission with merc 5 trans fluid. After that i started the truck for the hell of it.

DOH!!! forgot the transmission cooler lines. big oily mess!

Went back to northern performance where i got the bake hoses made to get some more brake hose retainer tabs for the front axle hoses. While i was down there i picked up a new trans cooler. Dropped off the last steering bits to have them machined so that i can weld them together, that will be ready tomorrow at 10ish.

Finished the brake lines. had to use a shitty ass flaring tool set. some of the connections leak a little. but i will deal with that when i get my good flaring tool fixed. Ran the trans cooler lines, mounted the cooler. tested the brakes by jacking up a front wheel holding the pedal on and trying to turn the wheel, felt good to me.

Modified the 5.0L thorttle cable bracket to recieve the ranger throttle cable. I used the half that bolted to the intake, cut it where it bends, drilled a hole in a piece of thin plate to recieve the cable and welded it together. works great.

Tomorrows plan is to pick up the power steering resevoir i ordered from work and the power steering pressure line, then pick up my bits from the machine shop, and play with some steering. After that its check that all the bolts are tight, and see if she will move under her own power. Theres still plenty to do, but My goal for the week was to get it to move under its own power. Looks like im winning so far.

[dude772]

And for the end of the week. I've accomplished my goal! I made the ranger "drive" for the first time in 3 years!

The power steering is hooked up, the pump if for a 98 explorer 5.0L the pressure line is the 98 explorer pressure line, the steel end on the line is 3/8, the pressure line for the steering box is 5/16. So instead of putting in a bunch of ugly compression fittings or adapters i had 2 choices. choice number one, cut the hose and bring it to a hydraulics place to refit the end with what i need. Or weld on a 5/16 line to the 3/8 line. and since i can always do option 1 if option2 fails, i welded away :D!

Worked fabulously. Flared the 3/8 line and used pliers to crush it around the 5/16 line and oxy-acetylene welded it together.

made my final steering link. The steering shaft coming off the steering column was modified to fit around the exhaust. I picked up a steering u-joint from bicknell racing products, its splined on one side to go directly onto the steering box and welded to a stock 4x4 steering shaft on the other with the rag joint removed. Clears but barely, but thats ok because im removing the garbage james duff headers and going for AA 4x4 headers.

Finally double check everything andput the gas pedal in started her up put it in gear and drive it forward a foot backward a foot and then forward again.

Time to get the finishing touches done to get it to safely drive down the road.

[Mechanickid]

:D You got me exited just reading that! Congratulations!

[bikerboy]

what's the update? Get different headers on it yet? steering and brakes all finished up? did you move stuff out of the way to drive it? come on man. i've been watching the build the whole time.

[dude772]

No new headers yet. Brakes done, steering done. Altho the steering box may need to be replaced, very sticky/ stiff turning left. Thottle cable done. kickdown cable lever and bracket fabricated, but may need tweeking, cable adjuster isn't working. I got the crap cleaned off the roof, and the windshield area, 80% of the crap in the back is cleaned out.

The shops still a mess, thats getting worked on. My next plan is to finish the drip rail, needs re-sealing. And order up a rear window so that i can take it out of the shop without water getting inside. Then i can take it to work and get alot more done.

Im waiting till payday to order anything else, i spent quite a bit in the past 2 weeks.

Good news is that with everything done so far, it starts with the key, runs, brakes hold, shifts into gear, and the thottle peddal will make the truck move forward and back were it sits in the shop.

[Duggo]

Nicely done!

[a-5 freak]

MORE UPDATES!!!!! You got me so exited! I wanna see this thing move!

[dude772]

MORE UPDATES!!!!! You got me so exited! I wanna see this thing move!

HAHA so do I! I ordered a bunch of tabs from ballistic yesterday, and some new headers from advance. i asked ahead of time what their policy is on headers that dont fit. They told me, "call us, get a return authorization number and pay for shipping back. no problems". So if these ones dont work, i'll try the other ones. I ordered their 4x4 5.0 conversion headers, non-plated.

Should be in soonish. Im getting my buddy who owns the shop to start clearing his crap out of my way to move it. Im picking up a new bolt-in style rear window, because i didn't like the gasket mounted origonal slider. So if anyone wants it, thats up for grabs if i can find all tha bits.

The urithane primer and urithane for the drip rails should be in, going to take care of that this weekend. Once the cab is sealed I can take it outside to work on in the sun, get a tan while i work.

Im excited. I will be sure to take a video of it driving out.



pics of the kick down lever i made up compared to the origonal
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00697.jpg

[dude772]

Holy crap ballistic ships FAST! I got my order in on Wednesday, took 2 days to get to me! That was awesome! Also picked up my urithane and primer. The plan for tomorrow is to seal up the cab, fasten the coils to the axle. And maybe I will try to get this thing running nicely.

I picked up a bolt-in style rear window. I was going to have my friend who does glass to order me one up for $180. But I checked kijiji.ca first. Found a NOS factory(as far as i can tell) never installed rear window 40 min away for $50. Had him take a few measurements for me to make sure it would fit. Picked it up wednesday night and test fitted it. PERFECT! Now I have the satisfaction knowing someone wont be able to break into my truck easily. Window also has a much better designed latch on it for the sliding window.

If anyone wants the old sliding window its yours for the cost of shipping, frame is kind of tweeked from storage, but the glass is good and untinted.


New installed, you can see how the gasket from the origonal covered alot more body than the new one

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00700.jpg


And the old one sitting on the box for the tonneau cover

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00701.jpg

Up for grabs for whoever wants it. If someone can make use of it. Maybe a trade for a grey supercab headliner?

[RedneckSTX]

Looking real good man, can't wait to see the finished product, keep up the good work.

[dude772]

This weekends update.

Got the cab sealed up. all the rear windows are installed. And the shitty old seam sealer is removed from the drip rails because it was all cracked and rusted/ rotten underneith.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00715.jpg

Seam sealer was replaced with Some nice urithane sealer. Its more flexable, and can be put on over 3 times thicker. It doesn't call for a primer on the can, but I used it anyway just because.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00714.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00713.jpg


I had pictures of after I layed a few coats of primer over the sealer and bare spots but I dont know what happend to them. Oh well.

After all that was done, came the huge task of moving shit out of my way to get the truck out of the shop. For anyone whos not familiar with how messy the shop is, browse threw a few old posts. Theres zero room to move, let alone pull the truck out. None of the front bumper had any view of an opening.

After a couple hours

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00710.jpg

And when I called it quits for the day

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00711.jpg

The orange bolt shelf was to the left approximately 4 feet, theres a light spot on the ground where it was. And there was tones of crap behind it where it is now. Including another 5.0L engine

Still need to toss in some rear axle seals and gear oil and put a cover on the front axle and install the remaining driveshaft bolts before it goes out, but Im close.

[dude772]

MORE HEADERS!!! :D

YAY! I finally got my new headers. The UPS guy tried to drop them off monday, but i wasn't going to pay for almost $70 in brokerage fees, so I called the UPS 1-800 number, bitched to them for about 5 minutes, they said that I can have them ship the package to windsor to declare it myself. I told them to go ahead and ship it to windsor, because im not paying that much in brokerage. They arrived in windsor yesterday, they called me and told me the amout for C.O.D which still included the brokerage fee, i told the rep that the last person told me i could send them there... blah blah blah. She said she would look into it and call head office. And surprisingly they showed up again today with a C.O.D of just the taxes.

But then i find out the driver only accepts checks. So away he goes with my headers AGAIN! :(. So i call the 800 number again give them the visa number over the phone to pay for the C.O.D taxes because the driver cant do it, which is bull shit. Anyway. Driver comes back at bout 4:00 and drops it off no problem.

Removed the old header from the drivers side, pain in the ass since with the james duff headers, they decide to put the mounting holes so close the the tubes that the hex on the bolts they supply hit the tube! only way to install and or remove is a wrench!

Trial fit the new header, PERFECT! fits in there and no pinion problems. Only thing to worry about is clearance on the steering shaft. But, I have a plan. Tomorrow at work im going to use my swing press (heavy hammer)to gentley form the header so that there will be plenty of clearance for the steering shaft.

It fits as it is now, but i want just a little extra. If i had these headers in the first place i would have been able to locate the engine slightly to the passengers side more for clearance, but shit happens and i learn.

I DEFINITLY recomend the Advance Adapters headers! Excellent fit and looks great. The only complaint about the product i have is that the tubes going into the main tube/collector protrude into the main pipe quite a bit and look as if they would be a restriction somewhat for a performance type engine. Im going to try and grind some away. But I dont see it as an issue for me.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00716.jpg

[dude772]

Forgot my phone on my desk when I left for work today. So no pictures for the update. I made some clearance in the drivers header. But I decided against the hammer approach. Instead I used my air hammer with special chisel bits that I bought for forming metal after I made the g/f a stainless steel rose for valentines. One large diameter convex round chisel, the other is a 3/4 diameter punch thats been ground into a convex. They are so I could make more of these roses without destorying my arm or more anvils.


Anyway! I used these bits to flatten out the outside of the collector pipe near the second cylinder. Then i used the larger chisel to feather the flat spot down the pipe so its no so strange looking. I will take pictures when I'm mounting them tomorrow. I also ground down the welds for the tubes, the weld was protruding into the tube such that it seemed to be quite a restriction. So I made it look much more open. Nothing i could do about the tubes protruding into the collector pipe tho, oh well. If it comes down to the point where i put high flow heads on and a better intake, i'm sure i will have enough money then to have the headers fabricated again to be a better flow design. But I dont see that happening. They are Great as far as im concerned.

Untill tomorrow. thats my update.

[dude772]

Axle seals installed, new headers modified and installed, proper spark plugs and new fuel filter installed, the plugs that were in there were just whatever i had laying around that would fit in there that was close to what i needed. I picked some of the Ford spark plugs up from work, cost me almost 2 bucks a plug, almost wasn't worth screwing around.

Discovered which camshaft i installed in the engine. I thought i put in the non-ho cam. apparently i put in the H.O cam. Who woulda thunk it. So now its running smoothly on 8 cylinders instead of 4 or 3.5. Starts within half a crank, so I am pleased about that. I set the rear pinion angle to where it looks good by eye, which is close enough for me. I broke the limited slip spring for the diff trying to put it in, so I'm just going to omit it untill I get the proper gears that i want.

Found my tool bag that had my driveshaft bolts in it. Put those in and finished installing the driveshaft. Next is front pinion angle, shocks and mounts. Maybe a hood.

Ordered a new T.V. cable, as in throttle valve, not boob tube. Should be in Tuesday.

Pictures of the modified header.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00720.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00719.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00718.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00717.jpg

[dude772]

And for the last update for the week. Just pictures.






http://i168.photobucket.com/albums/u193/dude772/Build/101_1662.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/101_1663.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/101_1664.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/101_1665.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/101_1666.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/101_1667.jpg

[DRIFTGOD187]

lookin good :icon_thumby:

[alabama0redneck]

looks good thats about how i want my truck to look nice build man

[mjonesjr]

I couldn't have waited almost 2 years.

Looks good.

[dude772]

I couldn't have waited almost 2 years.

Looks good.

Not almost, over.

[TheCiscoKid]

Great looking truck. Glad to see you got it done, gives me hope! What are your plans now? Paint? Or just wheel the tar outta it?

[dude772]

Not done yet, just moveable.

Broke the steering box bolts last night pulling the truck into the shop at work. one of the bolts was gnarly lookin from rust, the other was loose, and one was missing. So that let to SNAP! Couldn't do anything last night because it was too close to closing time, had to get up at 5am today at work by 6(we open at 8) and put it together this morning, then after we closed at 5 I worked on mounting the drivers side front shock. All was going well untill we ran out of mig gas for the welder.

Went to install the T.V cable... They ordered me a shifter cable instead! bastards!

Then I thought i would swap in my fancy stemless valves for the tires. They are awesome! Never going to be offroad, get to close to a stump, tree, or rock and tear off a valve.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00722.jpg

You can just make it out at the 4 o'clock position on the wheel. I only have a phone camera, excuse the quality.

[dude772]

Had to work today. And since I now have my ranger stored at work so that i can more easily work on it and such, between jobs and at lunch i puttered away at it a little.

Cleaned the body on it, Cut away the engine cross member where the TTB suspension bolted on. And for anyone who wants to try and correct TTB feel free to start at the begining :P.

And my Throttle valve cable finally came in, they ordered me the wrong part last time. Seems to work, the transmission T.V lever seems to have a full range of motion, but seems to not want to fully spring back, I will double check with the trans guy, I'm probably going to add an external return spring to the lever.

Its just the regular Ranger A4LD trans tv cable, but the lever on the trans is modified to work with it.

then at mid-day, some 17 year old lookin guy was in the shop checking it out with his dad, they were all over it loving it. Apparently the dad has a 1990 4x4 and the 17 year old has a 93 5.0 2wd with a fully boxed frame.

they were asking all kinds of questions about it all. They both seemed to be shocked at just how much work has gone into it. I was glad that people other than myself like what i've sent years building.


first clean in years
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00723.jpg


Bye bye useless steel!
http://i168.photobucket.com/albums/u193/dude772/Build/DSC00724.jpg
May reuse small sections to support my shock mounts.

[dude772]

Still pluggin away, trying to get it road worthy. I've been working till 9pm after hours working on this turd. I've gotten the shock mounts for the front done and then redone because i had a brainfart and put them where the tires want to be. I had to torch the tabs off and re mount them. I had to re-do the rear pinion angle, somewhere along the line of moving it around the axle has twisted. once i got it in place this time i taced the perches in place.

But what i didn't realize was that there was still penetrating fluid on the axle where i wanted to weld. so as soon as i touched the wire to the axle, POOF ball of fire in my face! That was kindda funny. Then today the Warn hubs and spindle nuts showed up.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00727.jpg

So i figured it would be a good time to replace the front rotors, wheel bearings, grease seals and install the front axle shafts, and do the shaft U-joints.

But I cant have these nice shiney new lockers on nasty crusty looking wheel hubs. So I had to clean those up and paint them. Started by tossing them in the varsal tank to get the greasr off, then hose it down, sand with 60 grit, die grinder with a sanding disc, acid bath, hose it again and dry then paint. turned out mint!

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00725.jpg

Installing the hubs was pretty straight forward, i could have gone without the spindle nut kit, but the origonals look like lots of people have used a screw driver to take them off in the past.

A few other things i got done were the coil spring retainers on the axle. Cut the head off of a 1/2 bolt and weld it to the spring bracket on the axle. paint the instrument cluster trim that covers half the dash. Got new bolts for the body to the frame and installed those.

Blah, still lots to go it seems.

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00726.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00728.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/DSC00729.jpg

[JD22]

wow that's sexy.

[dude772]

SON OF A BITCH!!! Took it off the lot onto the road for the first time. The first time its gone over 2km/h and the god damn son of a bitch didn't shift out of first!!!!!! Went to the corner to put $50 in the tank and it didn't come out of freakin 1st gear! Today i WAS going to have some exhaust pipes made up for it, but seeings how it cant go more than 5km/h i cant get the damn thing to the exhaust shop. So i spent the rest of the day messing around with the T.V cable and linkages and such, checking line pressures all that horse shit. And THEN the side tank on the rad blew apart, i knew it had leaks so i ordered a new one, but it never showed up. So now i have a trans that goesn't shift and a rad that doesn't hold fluid.


BAH!!!!! bad freaking day. This junk is all supposed to just work, we had the trans apart and had the ford dealer transmission specialist build the trans with me, its supposed to just work! damnit!

This was supposed to be on the trails next week, but unless everything is figured out and done by the end of monday, its just not going to happen.

[venom97]

looks bad ass! damn trans issues! im fighting em too! lol keep it up,its looking like a fun ride!

[dude772]

looks bad ass! damn trans issues! im fighting em too! lol keep it up,its looking like a fun ride!

It better be fun, cause im pissed at it. Im going to take a look at the gov today because ive beat the tv linkage to death and the way its setup should give me some kind of shifting. we have tried everything with the tv linkage, theres nothing left to try but the gov.

[DRIFTGOD187]

sorry to hear that, good luck.

[big91explorer]

Hey, I completely restored a 91 Trand Am, and the damn thing did the same thing. Have you tried running it through the gears manually? Sometimes that will work.

Dont get frustrated and sell it like I did, 'cause now I really regret it. That's a bad ass truck.

[dude772]

Yea, i've tried going threw gears manualy, and its not the gov. I guess this things just flat out not going anywhere this week. Monday I'm going to bring it over to get the exhaust made and leave it with them while im away with the explorers.

Basically all i got done was put the rad in. I took the t-case out and the tail housing to check the gov, found nothing wrong with it at all. So I'm going to try using the proper 5.0L T.V setup. I called a guy today about getting the bits i need off a mustang, left a message with him.

And from my rather short drive, I have a feeling that i may need to mess around with the front shocks some more, play around with the mounting locations. Bah, I just want to drive it! haha

[dude772]

I've been neglecting my build thread. I've gotten it to shift, not nicely, but it went up to third gear. I picked up a spare trans from a 3.8 thunderbird, took the tv cable and lever swapped to my truck. Took it to the exhaust shop. Had them make some front pipes and put my cats on.

I put a factory cd player in from a thunderbird with a facotory amp. Got another set of wheels for the truck, they aren't nice at all, but good for a couple spare tires. My uncle bought 31s for his truck and the rims came with them, im not going to turn down free wheels!

Hooked up the speedo with the speed sensor from the thunderbird trans. I re-wired the alternator harness to accept an explorer style alternator, because im cheap and had one sitting around.

im not sure what ive gotten done haha. All i know is that the tv cable still needs adjusting before i can drive the bastard.

[Downey]

sweet build man but how the hell did you work with a shop like that i would go nuts

[dude772]

Well I've made a little noticeable progress in the past 2 days. I bought up some more steel, a 2x4 with round a quarter inch wall, and some 1.5inch square tube.

http://i168.photobucket.com/albums/u193/dude772/HPIM3379.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3380.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3381.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3382.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3383.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3384.jpg

http://i168.photobucket.com/albums/u193/dude772/HPIM3385.jpg

Made use of the explorer swaybar bushing mount location, and welded in a nice beefy crossmember.

The shocks are for a 4x4 f250 with highrider package if i remember correctly. Not sure, I bought the shocks 3 or 4 years ago. All i remember was that i bought them on sale and ordered the biggest ones i could think of.

Maybe tomorrow i will work on setting up the e-brake, and trac bar bolt. I accedently stripped the 30 year old nut, oh well.


And for the record I bought a new daily driver. 2005 Escape Hybrid 4x4. I've gone threw 5 vehicles building this turd! haha. No pictures of it yet, but i will soon.

[dude772]

Im really slackin on this. Recent updates are installed and fabricated brackets for the ebrake cables. I used the front cable from the ranger and the rear cables adjuster/equalizer from the 91 f-150. Worked out great. The brackets are made from Escape lower control arms that I replace all the time at work and had some in the scrap bin. Figured they are beefy enough and cheap(FREE!).

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3386.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3389.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3387.jpg

The exhaust is done, but i havn't gotten pictures of it all yet, only the front portion. Yes I put cats on it, I want to make sure this trucks legal WHEN i get pulled over, its not a matter of if, its when im not going to try and fool myself. Its nice and quiet at idle and its got a little rumbble when i give it a bit of throttle. Its exactly how i wanted it. 2.5" all the way back. No cross-over pipe. I will get more pictures later but for now...

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3390.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3392.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3393.jpg

Next is the power windows that were installed on the truck quite a while before it came off the road. They were never actually wired up, i left the wires exposed under the dash near the center. When i needed a window up or down i stuck the wires in the cigatrette lighter. But for the first time they are fully functional.

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3397.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3398.jpg

[dude772]

For another update. The Alignement was set. When I narrowed the front axle 6" i tack welded the passengers side inner "C". Enough that i knew it would hold together enough for temporary slow speed driving but not too much to grind off. This was so that i could measure the caster on the alignement machine.

I set the caster angle according to the 4x4 ranger factory specs. The caster i had it at was only 1 hammer swing away from the spec. It was in specs, but not close enough. Then tac it back on with the shop welder untill i can use my buddys big welder to make it solid.


After setting the alignement, I decided it was time for a maiden voyage! I needed to transport the truck to my buddys place to do some welding on the axles and frame. No better time than the present! Threw a dealer plate on the back and took it for 10 - 15km drive. Good news is that it drives better than it did when I drove it last(3 years ago!). Bad news, throttle cable still needs adjustment, wont get into 4th, and forced upshifts. But it is driveable!

That mean I WIN! For everyone who ever doubted me and said that "[i] cant to that". I showed them that I can! I tore this thing apart, and completely rebuilt it and made it go down the road again! I gave it new life!

Next step is transfer it into my name from my dads(when i purchased it at 17 we licenced it under my dads name), new plates and call the insurance company.

[dude772]

Passengers side inner "C" welded on solid, rear spring perches welded on solid, and trac bar welded on solid. Now i feel safe going over some roughness. Still waiting for the Ballistic front diff cover i ordered a month ago, not too pleased about that.

[dude772]

i promised pics of the rest of the exhaust.

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3401.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3402.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3403.jpg

ANd to get pictures of the exhaust this is what i did.

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3412.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3407.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3408.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3410.jpg

[dude772]

Found that the brake pedal feels a little funny on the truck, seems to me that its either the brake booster is fooked, or the solenoid for the RABS. Seeings how its going to cost around $100 for a booster and god knows how much for that solenoid deal. I decided to buy the parts stores retired 90 reg cab long box ranger thats got 440 000 kms.

Brought it home today, and going to tear it apart tomorrow after work. Any concevable part i may need in the future im pulling off this thing then bringing it in for scrap and get most of my money back. And this way, I can get the few parts I cant seem to find to finish things off.

[multiranger]

Sweet looking ride... Helluva job!

[twoll86]

did the bigger drums from the f150 just bolt in to place?

[dude772]

did the bigger drums from the f150 just bolt in to place?

Haha yes they just bolt into place once you remove the axle shafts from an f-150 have them shortened and re-splined and install them into an explorer rear axle.

But if the question is do the backing plates bolt onto the axle, the answer is yes they are a direct bolt on. The tuff part is the axle shafts. You can have them custom made cheaper from Moser with a lifetime warrenty. The problem i had with that was a crap load of measurements that i would have to take off both axles. What i did was took 4 shafts to True Gear in cambridge and told them i need the long ones the smae size as the short ones.

[dude772]

Got my diff cover from ballistic finally. A little complication with shipping and took alot longer than i would have liked. But I got it. As soon as i got it in the mail, I took it to Metal Works in Caledonia and had them powdercoat it for it. cost $25 to get that done. Seemed good enough to me. They put the coat on THICK! they almost made the weld ribs disappear.

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3436.jpg

http://i168.photobucket.com/albums/u193/dude772/Build/HPIM3430.jpg

[dixie_boysles]

what a build!! now just get that truck all one color!

[TheBeast]

Damn. Sweet ass truck man

[dude772]

what a build!! now just get that truck all one color!

As soon as i can afford a paint job it will be 1 colour.


AS a side note, last night I put the new licence plates on it, and the insurance card in the glove box. It is now legal for me to drive it. Took it for a good long drive last night, found a few issues that need to be sorted out, but nothing too major. Still needs the throttle valve cable adjusted. Im not really liking the choice to use an automatic. Standard would be the way to go if i were to do this all over again. Or maybe next time, dont work in a messy ass shop and loose everything. So i would have had the origonal t.v cable and all the linkages.

[twoll86]

Haha yes they just bolt into place once you remove the axle shafts from an f-150 have them shortened and re-splined and install them into an explorer rear axle.

But if the question is do the backing plates bolt onto the axle, the answer is yes they are a direct bolt on. The tuff part is the axle shafts. You can have them custom made cheaper from Moser with a lifetime warrenty. The problem i had with that was a crap load of measurements that i would have to take off both axles. What i did was took 4 shafts to True Gear in cambridge and told them i need the long ones the smae size as the short ones.

couldnt you have had the explorer axles re drilled for 5*5?