Aerostar 4X4

[Rulebreaker]

My BroncoII is too small for my whole family to go wheeling with so I decided that the BroncoII would become my "off road park rig" and that I would build a rig for the 7 of us to do the light wheeling in. So I bought a 93 2wd aerostar to build along with a 4wd aerostar and 4wd Ranger for parts. I plan is to use the stock 4.0L along with a Ranger tranny and a 1350 Doubler tcase. It will get a D44HP front axle with the steering from the donor truck and a FW8.8 in the rear. Here are some pic's of the project so far.
http://inlinethumb57.webshots.com/13304/2863366340040927262S600x600Q85.jpg
This is what it looked like bringing her home.
http://inlinethumb01.webshots.com/10048/2289037830040927262S600x600Q85.jpg
http://inlinethumb06.webshots.com/12293/2638979810040927262S600x600Q85.jpg
I riped all the stock suspension out and put leafs in the rear.
http://inlinethumb07.webshots.com/12102/2807911320040927262S600x600Q85.jpg
http://inlinethumb29.webshots.com/13404/2293225480040927262S600x600Q85.jpg
http://inlinethumb31.webshots.com/12318/2793944620040927262S600x600Q85.jpg
http://inlinethumb09.webshots.com/13192/2983886250040927262S600x600Q85.jpg
Picks of the rear suspension installed using an F150 8.8.
http://inlinethumb53.webshots.com/7476/2811482810040927262S600x600Q85.jpg
http://inlinethumb01.webshots.com/5696/2393675510040927262S600x600Q85.jpg
http://inlinethumb42.webshots.com/5801/2500016840040927262S600x600Q85.jpg
http://inlinethumb63.webshots.com/766/2471468990040927262S600x600Q85.jpg
I have a TK4, FM145, and a C5 to choose from for a tranny so I'm starting with the TK4. I know they are week but nothing is permanent.
http://inlinethumb17.webshots.com/14224/2726830880040927262S600x600Q85.jpg
http://inlinethumb20.webshots.com/9427/2396478840040927262S600x600Q85.jpg
http://inlinethumb30.webshots.com/11229/2655989420040927262S600x600Q85.jpg
These pic's give you a good idea of what she will look like when finished.
http://inlinethumb23.webshots.com/12630/2524784390040927262S600x600Q85.jpg
I still need to fix the problem of the door hitting the rear wheel, I need to lengthen the line going from the clutch master to slave. I need to build the doubler (next project) and need to get my front axle as the first one was stolen. I will post pic's as it gets done. I hope to finish it by spring. RB

[BDAB]

convert it to barn doors maybe.............. Looks good. definitely unique..... all the off road Aerostars I have seen were Aerostars on a F-150 frame. Good work.

[kunar]

glad to see this project found its way to the new forums. lookin good, keep us updated

[Rulebreaker]

convert it to barn doors maybe.............. Looks good. definitely unique..... all the off road Aerostars I have seen were Aerostars on a F-150 frame. Good work.

I feel that the aerostars frame is heavy enough to build on and that the added weight of the truck frame would be more of a hindrance than help. RB

[samsonitesamsonite]

looks good! a little constructive criticism... those shackles look a little on the flimsy side.

[Rulebreaker]

looks good! a little constructive criticism... those shackles look a little on the flimsy side.
I agree they need some gussets I actually have a better set but I'm just mocking it up right now. RB

[Sunk]

Cool man, I've been waiting to see more on this project. It looks pretty badass with those Iroks under it. How big are they?

[racsan]

on the side -door issue, could you lenthen the link to clear the tire? have seen full-size vans with big tires that used a extented link to let the door be further out when open. or put enough of a lift on that the tie is completly below the door when open. (may need step-bars to get in though)

[Rulebreaker]

Cool man, I've been waiting to see more on this project. It looks pretty badass with those Iroks under it. How big are they?Those were 37" but i think I'm going to run a 315/75/16 as I have a set of 16" rims just like the ones the iroks are mounted on. RB

[dude772]

When i was growin up we had 5 aerostars! And its the ONLY van i wouldn't mind owning. Expecially that one hahaha. Thats pretty friggin awesome man!

[Sunk]

Cool, I can't wait to see some action shots.

[86ford]

i like the clutch pedal that stands out like a sore thumb. i am half intrested in finding a AWD van to build myself. i would find entertainment in having a rig with a cooler, bed, and generallly unique.
86

[ZMan]

I wonder how long that transmission will last behind the 4.0l? Should be a perfect test for it. Cool project.

[Rulebreaker]

i like the clutch pedal that stands out like a sore thumb. i am half intrested in finding a AWD van to build myself. i would find entertainment in having a rig with a cooler, bed, and generallly unique.
86

Don't forget the porta potty! Remember I have 5 daughters. RB

[Rulebreaker]

I wonder how long that transmission will last behind the 4.0l? Should be a perfect test for it. Cool project.
It's like putting a 20amp fuse in a 30 amp draw. I'm never easy on things either so we will soon know. RB

[hairyboxnoogle]

Convert your side door to suicide or Lambo style! lol, that would work. This thing is awesome.

[Rulebreaker]

Convert your side door to suicide or Lambo style! lol, that would work. This thing is awesome.

I've got 100 idea's on how to do the door but it will be the last thing I do. I was thinking i would flip the top half up and the bottom half down and put steps on the inside of the bottom half but who know's what I'll actually do. RB

[ZMan]

Convert your side door to suicide or Lambo style! lol, that would work. This thing is awesome.

bahh best ones I could find..
http://www.goezcustoms.com/feature_images/goez_feature3b.jpg
http://www.weekendtoys.com/catagories/eventsphotogallery/2005/goezcustoms/pictures/goez04.jpg
people need to lay off the resize button!
heres a few more..
http://www.goezcustoms.com/feature_images/goez_feature3.html

[samsonitesamsonite]

I don't know whats wierder that fact that someone thought about suicide doors on a mini, or the fact someone did it...

[ZMan]

I don't know whats wierder that fact that someone thought about suicide doors on a mini, or the fact someone did it...

I've always wanted to customize an Aerostar, but they are probably the worst vehicle ford made when it comes to rust prevention, meaning they are impossible to find in good shape in this area...mine would have been custom but all of the panels were crap except for the fiberglass hood and hatch, and somehow the fenders were still perfect.

[AllanD]

An aerostar is a LOT lighter than you think it is... even the 4.0AWD model only runs about 3500lb

That being said I see from the PICS that you used a TK-4 trans?

I like the leaf springs, but I'd have boxed about a 1foot section of
the subframe rails where you attach the shackles to the unit body.

I like the whole idea, but when I thought about doing something similar
I was thinking of using a Gen2 explorer frame (sectioned appropriatly)

I like the whole idea, but the TK4? that's just f'in nuts.

AD

[ZMan]

An aerostar is a LOT lighter than you think it is... even the 4.0AWD model only runs about 3500lb

That being said I see from the PICS that you used a TK-4 trans?

I like the leaf springs, but I'd have boxed about a 1foot section of
the subframe rails where you attach the shackles to the unit body.

I like the while Idea, but when I thought about doing something similar
I was thinking of using a Gen2 explorer frame (sectioned appropriatly)

I like the whole idea, but the TK4? that's just f'in nuts.

AD

ya theres not too much to them. When I was stripping the interior in mine to get it ready for the radio hammer smash promotion thing, I realized they have very little crash protection...all they've got is the exterior sheetmetal, theres nothing on the inside!

[Rulebreaker]

I like the whole idea, but the TK4? that's just f'in nuts.

AD

I've got a C5 if it doesn't work. It's only like an hour job to change it so i don't see it as a big deal. RB

[Rulebreaker]

ya theres not too much to them. When I was stripping the interior in mine to get it ready for the radio hammer smash promotion thing, I realized they have very little crash protection...all they've got is the exterior sheetmetal, theres nothing on the inside!

Have you ever looked at a Saturn? If you get hit from the side the only thing protecting you is a plastic door panel and a steel bar that two guys can bend by hand. I know as i bent one back for a lady who hit a mail box and then her window wouldn't roll up because the bar was bent. By looking at the car there was no visible damage. I'd ride in an aerostar and feel safe before I'd sit in a parked SL1. RB

[Joe_Roofer]

Hey Rulebreaker,
your living up to your name with this project, I like it.
Theres a guy out here trying to sell a '97 4.0 with 80K
AWD, needs a wheel bearing and some rocker panel work
on drivers side for $799. I don't know much about these
vans, sound like a good deal? I think so...

[Loanranger]

So hows this project of yours coming along? Any recent pics?

[Rulebreaker]

Hey Rulebreaker,
your living up to your name with this project, I like it.
Theres a guy out here trying to sell a '97 4.0 with 80K
AWD, needs a wheel bearing and some rocker panel work
on drivers side for $799. I don't know much about these
vans, sound like a good deal? I think so...

That sounds like a good deal. The tranny is the weak spot on these just like the Ranger&Explorer. RB

[Rulebreaker]

So hows this project of yours coming along? Any recent pics?

It's been on hold as I've painted my wife's van, and put new fenders,doors,&bed on my truck plus given it a paint job. I'm pulling the tranny out of my truck and then I'll get back at the Aerostar. Once I get the front axle for the van it wont take me long to finish it. RB

[ZMan]

Have you ever looked at a Saturn? If you get hit from the side the only thing protecting you is a plastic door panel and a steel bar that two guys can bend by hand. I know as i bent one back for a lady who hit a mail box and then her window wouldn't roll up because the bar was bent. By looking at the car there was no visible damage. I'd ride in an aerostar and feel safe before I'd sit in a parked SL1. RB

meh I'd drive them both without hesitation. I've seen enough t-boned saturns to know they actually hold up.

[badblue]

I work at a scrap yard and vans are the strongest of all as far a crushing and smashing them But all are distoid. Have not had one that can with stand the shedder.

[THE WHITE RHINO]

interesting yet i just threw up in my mouth a little

[AllanD]

ya theres not too much to them. When I was stripping the interior in mine to get it ready for the radio hammer smash promotion thing, I realized they have very little crash protection...all they've got is the exterior sheetmetal, theres nothing on the inside!

Yeah, But I've seen some hit spectacularly hard and the interior looked like the driver in one particular vehicle would have had serious leg injuries, but anyone aside from the driver actually wearing a seatbelt would have
atleast staggered away (Nobody walks away from a hard impact like
nothing happened).

The engine in my van was originally from an aerostar that
suffered a hard right front impact that was ssevere enough
that both the passenger door and the sliding door were
"traumatically amputated" from the vehicle, along with
the right side suspension...

Before the vehicle rolled onto it's drivers side and slid to a stop.

Unless the passenger had a death grip on the inside door handle
they probably would have needed fresh underwear, but other
than the smell and embarrassment...

(that accident must have resembled the crash scene at the
beginning of "Pitch Black")

Roll an aerostar and the interior retains it's shape, but an OFFROAD
roll-over could involve a vertical drop, So I'd be inclined to add some
sort of reinforcement.


AD

[texasranger]

That's an awesome project! I've thought of it in the past, but was thinking that the Aerostar frame, having the Ranger type front end, would somewhat readily adapt to factory 4x4 parts. Is there some truth to that or am I way off base? Either way, thanks for sharing.

[Rulebreaker]

That's an awesome project! I've thought of it in the past, but was thinking that the Aerostar frame, having the Ranger type front end, would somewhat readily adapt to factory 4x4 parts. Is there some truth to that or am I way off base? Either way, thanks for sharing.The entire drive train is Ranger compatible but there are some differences. The T case is different but a Ranger one will bolt up. The front axle is a Dana 28 but is entirely different than the Ranger one. The rear axle is about 3" wider than a Ranger but otherwise the same. Suspensions are two different animals altogether. RB

[AllanD]

The Aerostar uses a double-wishbone front suspension with coil springs.

And a three link suspension on coils in the back.

The only things actually common are:
1) the companion flange on the rear axle is common to the '90-up RBV's
2)The brake calipers and brake pads are common to the '83-94
(except SOME '86-87's)
3) the mating flange on the trans where the T-case bolts up uses
the same 5bolt pattern.

And for reference sake only, the 4.0 engine used in the Aerostar
is identical to the explorer engine EXCEPT for the exhaust manifolds
(yeah the accessory brackets are all the same)

AD

[texasranger]

Wow. So I was a ways off. Thanks for the information. I had thought that the front end was more similar than that....Been awhile since I looked at one, I guess.

[Rulebreaker]

Wow. So I was a ways off. Thanks for the information. I had thought that the front end was more similar than that....Been awhile since I looked at one, I guess.

The Ranger and Aerostar both had the same line of engines except the Aerostar never had the 2.9L. Both had A4LD,tk4,tk5, and M50d's, Both had Dana 28 front axles and Both had 7.5 and 8.8 rear axles. But dont be fooled they are difdferent animals. RB

[Rulebreaker]

WOOOOOHOOOOOO

http://inlinethumb32.webshots.com/20191/2660942500040927262S600x600Q85.jpg
http://inlinethumb64.webshots.com/23551/2901982620040927262S600x600Q85.jpg

[Todd]

HP D 60,:icon_hornsup: right:icon_confused:

[Rulebreaker]

HP D 60,:icon_hornsup: right:icon_confused:

It's ultra rare as it came with C wedges and was pulled from a Escort GT. RB

[Rulebreaker]

I slid it under there and did a mock up. Looks like the coils will line up with the buckets. Track bar will need some work. I ordered new 7 degree bushings for the front today, but it looks like I'll need to use drops for the radius arm mounts. I'm not sure how much. I'll have to get some idea's on how to tell how much to drop the mount. I 'll probably have to do some clearancing around the pig so I can have some more up travel.
http://inlinethumb20.webshots.com/24723/2697237550040927262S600x600Q85.jpg
http://inlinethumb27.webshots.com/25370/2658300950040927262S600x600Q85.jpg
http://inlinethumb52.webshots.com/23027/2417414100040927262S600x600Q85.jpg

[Sunk]

Sweeeeet. Looking good.

[rusty ol ranger]

I never was fond of aerostars......but that one is going to be bad ass.

later,
Dustin

[PARKINGLOT]

sweeeeet...

[Rulebreaker]

I got the 7 degree bushings installed and I'm going to have to build a 8" radius arm drop to get to 3 degrees caster. I was hoping I wouldn't have to do that. I'm debating if it's worth the work to knock the knuckles off and re weld them on instead of dropping the radius arm. RB

[Rulebreaker]

The axles are now holding her up front and rear!
I'm shocked on how well the spring buckets lined up. All I did was turn the lower one so it faced in instead of out.
http://inlinethumb52.webshots.com/28787/2702119160040927262S500x500Q85.jpg
Right 68 Bronco spring.
http://inlinethumb11.webshots.com/27850/2558886040040927262S500x500Q85.jpg
Track bar mount. (I'll be beefing it up some more)
http://inlinethumb63.webshots.com/27518/2414609430040927262S500x500Q85.jpg
Left spring.
http://inlinethumb28.webshots.com/28379/2419697480040927262S500x500Q85.jpg
Left radius arm mount. It's a section of Ranger frame that I boxed. I still need to weld it to the frame and add another brace at the rear.
http://inlinethumb60.webshots.com/28603/2713230650040927262S500x500Q85.jpg
Tranny X member. It's half Aerostar half Ranger.
http://inlinethumb19.webshots.com/28882/2182872690040927262S500x500Q85.jpg
Left Radius arm mount.
http://inlinethumb57.webshots.com/29688/2396263600040927262S500x500Q85.jpg

I need to get all the parts from the spindle out to finish the front axle and I need to build the steering yet. Long way to go. RB

[Rulebreaker]

I pulled the power steering box out of my parts B2 and it looks like I'll be able to make it work. It will be a pain to to build a bracket, but i think i can make it work. I'll post pic's when i get it installed. RB

[86ford]

It's ultra rare as it came with C wedges and was pulled from a Escort GT. RB

okay, i know i am a little late asking but what am i missing? you have a front solid axle from a escort gt??? i am really really confused!

[Rulebreaker]

okay, i know i am a little late asking but what am i missing? you have a front solid axle from a escort gt??? i am really really confused!

All FX4 Escorts came with a D60 that had C wedges. Very rare car!:D

[86ford]

All FX4 Escorts came with a D60 that had C wedges. Very rare car!:D

ok sooo now that i am beyond perplexed with this whole idea i need pictures!
this is completely new to me!

[Rulebreaker]

Got the pedals fixed tonight.
http://inlinethumb33.webshots.com/27232/2784887510040927262S500x500Q85.jpg

[Woody88]

man this is awsome, and i thought a caravan with a turbo dayton engine was a cool van

[predator]

i love what you are doing man...wish i could see the buildup in person:icon_hornsup:

[Rulebreaker]

i love what you are doing man...wish i could see the buildup in person:icon_hornsup:

I cant wait to get it out of the garage so I can take some good pic's of her. I just hope she can wheel after all this work. RB

[86ford]

but nothing else you will have the only grocery getter going out in 2 feet of snow! it would be fun to wheel a van!

[Rulebreaker]

Mounted the power steering box today. I had to shorten the shaft to the box 2". I used a box from a BroncoII and the stock shaft bolted right to it. Bonus!
http://inlinethumb63.webshots.com/29694/2309556920040927262S500x500Q85.jpg
http://inlinethumb51.webshots.com/27954/2567833050040927262S500x500Q85.jpg
http://inlinethumb52.webshots.com/30835/2954053300040927262S500x500Q85.jpg
http://inlinethumb44.webshots.com/17579/2932680250040927262S500x500Q85.jpg
RB

[Rulebreaker]

Aerostar debut! No where near done, but She is out of the garage for the first time in months!
http://inlinethumb41.webshots.com/28200/2823182920040927262S500x500Q85.jpg
http://inlinethumb39.webshots.com/30694/2878223260040927262S500x500Q85.jpg
http://inlinethumb64.webshots.com/28223/2990637230040927262S500x500Q85.jpg
http://inlinethumb30.webshots.com/30109/2953779830040927262S500x500Q85.jpg
http://inlinethumb03.webshots.com/27522/2004345890040927262S500x500Q85.jpg
RB

[Sunk]

Sweet, it moves! Looks good.

[badkarma]

I think you should have moved the front axle forward a couple of inches. What about the angle of those radius arms? seems more than 7 deg.

[Rulebreaker]

I think you should have moved the front axle forward a couple of inches. What about the angle of those radius arms? seems more than 7 deg.

I agree it would be nice to have it farther forward but I didn't want to move the upper coil buckets, and the steering would have been much more difficult also. The caster is between 3&4 degrees. I used 7 degree bushings and built a 8" radius arm drop. You have a good eye for being a 100 years old.RB

[metalmacguyver]

that thing is awsome! my family had an old aerostar van. i wouldnt mind building one of those. so what years did the escorts come with D60s?

[Rulebreaker]

that thing is awsome! my family had an old aerostar van. i wouldnt mind building one of those. so what years did the escorts come with D60s?

Escorts built in 79 that had the FX4 package came with the D60. :haha: RB

[86ford]

i see i am not the only dumb **** who is lost on the whole idea of a d60 in a escort!
i think this sums it up
:dntknw:= first reacton
:idiot:= after rulebreaker told me the truth
:flipoff: my opinion
:sexe: rulebreaker making up for being a asshole
:icon_cheers:
:idiot: but in the end i am still a retard and rulebreaker did a great job of fooling a special needs student

:joke: i was :owned:

[Rulebreaker]

i see i am not the only dumb **** who is lost on the whole idea of a d60 in a escort!
i think this sums it up
:dntknw:= first reacton
:idiot:= after rulebreaker told me the truth
:flipoff: my opinion
:sexe: rulebreaker making up for being a asshole
:icon_cheers:
:idiot: but in the end i am still a retard and rulebreaker did a great job of fooling a special needs student

:joke: i was :owned:

ROTFLOL! That makes 2. I never dreamed anyone would take the hook. Live and learn.RB

[predator]

wow....thats an awesome job rulebreaker!!! when will it move under its own power???

[Rulebreaker]

wow....thats an awesome job rulebreaker!!! when will it move under its own power???

Soon. I'm pulling the BroncoII in the garage tonight and parting it out. What I don't use on the van will be for sale. RB

[metalmacguyver]

i see i am not the only dumb **** who is lost on the whole idea of a d60 in a escort!
i think this sums it up
:dntknw:= first reacton
:idiot:= after rulebreaker told me the truth
:flipoff: my opinion
:sexe: rulebreaker making up for being a asshole
:icon_cheers:
:idiot: but in the end i am still a retard and rulebreaker did a great job of fooling a special needs student

:joke: i was :owned:


:icon_rofl:

[predator]

well its been a little while....how is the progress coming now??

[Rulebreaker]

well its been a little while....how is the progress coming now??
I hope to have it back in the garage this week. My house is for sale and the garage has been looking terrible since I started this project, so once I had the Bronco II's parted out my garage floor disappeared. I built some huge shelfs and hung them 3' from the ceiling then I finished hanging the ceiling drywall and then painted the garage. I still have some stuff to finish in the garage and as soon as that is done it's coming back in and I'm going after it again. I need to sell some more B2 parts so i can buy lockers and bumpers. RB

[Rulebreaker]

I ordered a front bumper for the front today. I'm just not sure what i want it to look like. The guy will be over this week so we can kick some idea's around. If anyone has a pic of a front bumper that would look cool post it up. Also I'm thinking about ordering a pair of Aussie lockers. However if you go http://www.offroadlockers.com/make.php/TM83e57d/83ed/06/.html
here you will see that an 83-86 8.8 is $40 cheaper than a 87 & newer. Anyone know why? Thanks RB

[Rulebreaker]

I finished the steering for now. I'm going to put something on top of the knuckles once the van is finished. Here are a couple pic's.
http://inlinethumb17.webshots.com/34128/2921082220040927262S500x500Q85.jpg
http://inlinethumb53.webshots.com/35380/2763151950040927262S500x500Q85.jpg
It's built using an Explorer PS box. Drop pitman arm from Broncograveyard, the drag link is off an Explorer, and the tie rod is off an F250. I cannot find the power steering hose I was using on the B2 for the life of me. So I'm not sure if I will need to make a hose or if the B2 will work. I'm also not sure if a pump for a rack and pinion will run a PS box, so only time will tell. RB

[Rulebreaker]

I finished the steering for now. I'm going to put something on top of the knuckles once the van is finished. Here are a couple pic's.
http://inlinethumb17.webshots.com/34128/2921082220040927262S500x500Q85.jpg
http://inlinethumb53.webshots.com/35380/2763151950040927262S500x500Q85.jpg
It's built using an Explorer PS box. Drop pitman arm from Broncograveyard, the drag link is off an Explorer, and the tie rod is off an F250. I cannot find the power steering hose I was using on the B2 for the life of me. So I'm not sure if I will need to make a hose or if the B2 will work. I'm also not sure if a pump for a rack and pinion will run a PS box, so only time will tell. RB
I had one of the engineer's at Ford look into the steering pump dilemma, and he said he's 90% sure i need to change pumps. So hopefully one of my RBV pumps will bolt up and take the serpentine pulley. I'll know shortly. RB

[Rulebreaker]

I had one of the engineer's at Ford look into the steering pump dilemma, and he said he's 90% sure i need to change pumps. So hopefully one of my RBV pumps will bolt up and take the serpentine pulley. I'll know shortly. RB

I put a BroncoII pump in and it bolted right up and the serpentine pulley fit perfect, so the steering is finished for now. I figured the steering would be the toughest part, but it went quite smoothly. RB

[metalmacguyver]

....

that steering link looks a bit sketchy.

[BLOODBANE]

Looks like its coming along great. Keep us posted......

[Rulebreaker]

....

that steering link looks a bit sketchy.

Good enough to roll it in and out of the garage. I want to taper the knuckles from the top down and put a stock tie rod across and then find a drag link the right length to bolt to it, or maybe I'll get lucky and the explorer one will be the right length. RB

[rickcdewitt]

here you will see that an 83-86 8.8 is $40 cheaper than a 87 & newer. Anyone know why? Thanks RBthe cross pin is smaller on the early 8.8 and it won't interchange.

[Rulebreaker]

the cross pin is smaller on the early 8.8 and it won't interchange.

I emailed them and it's $40 cheaper because they are overstocked. RB

[Hardwareman]

Man, that thing is going to look awesome when it's done!

Don't worry about the negative comments as we all know this is a trial and error project and if something won't work you'll find out soon enough and make the necessary repairs.

At least you're being very consistent on it. It WILL pay off in the end......believe me! Keep the posts coming. I can't believe I have'nt seen this thread before.



Allen

[metalmacguyver]

ok as long as that isnt even remotely permanent. i like this project and i am glad to hear that. you said its supposed to be a family wheeler but that would be a serious safety compromise.

everything else is looking good!


edit: i realize what i posted earlier came off as a negative comment. i am sorry about that. i will say it again, i really like this project and only mean to provide positive feedback and constructive critisism.

KEEP UP THE GOOD WORK!!!!

[Rulebreaker]

Man, that thing is going to look awesome when it's done!

Don't worry about the negative comments as we all know this is a trial and error project and if something won't work you'll find out soon enough and make the necessary repairs.

At least you're being very consistent on it. It WILL pay off in the end......believe me! Keep the posts coming. I can't believe I have'nt seen this thread before.



Allen

Thanks! I hope to have the doubler in it tomorrow with working shifters. I also hope to order a pair of these http://www.offroadlockers.com/images/XD-14430.jpg
tomorrow. RB

[Rulebreaker]

ok as long as that isnt even remotely permanent. i like this project and i am glad to hear that. you said its supposed to be a family wheeler but that would be a serious safety compromise.

everything else is looking good!


edit: i realize what i posted earlier came off as a negative comment. i am sorry about that. i will say it again, i really like this project and only mean to provide positive feedback and constructive critisism.

KEEP UP THE GOOD WORK!!!!

Constructive criticism leads to improvement. It's been a real pain in the but taking it in and out of the garage without steering so i'm glad to have it steerable. I'll deal with the steering when it comes time to do an alignment. I was looking and a 79 tie rod is only like $70 but that wont work unless I put it on top of the knuckles because the drag link and track bar need to be at the same angle. Thats why I stacked the attachment point so I'll know if it has bump steer. RB

[metalmacguyver]

Constructive criticism leads to improvement. It's been a real pain in the but taking it in and out of the garage without steering so i'm glad to have it steerable. I'll deal with the steering when it comes time to do an alignment. I was looking and a 79 tie rod is only like $70 but that wont work unless I put it on top of the knuckles because the drag link and track bar need to be at the same angle. Thats why I stacked the attachment point so I'll know if it has bump steer. RB

:icon_thumby::icon_cheers:

[Black'03LevelII]

Once this ridiculously awesome build is done Ijust might have to drive my silly self up to MI to see this thing in person!!

[Rulebreaker]

Once this ridiculously awesome build is done Ijust might have to drive my silly self up to MI to see this thing in person!!

One of the plant managers at Ford wants to see it too so i might be driving it down to Detroit. They want to put it on the internal ford web site. RB

[rickcdewitt]

the aussie may be overstocked but a guy on pirate is selling an early 8.8 version new in box because he said it won't work since the cross pin is smaller.he may be wrong if so it would be a good deal-150$
http://www.pirate4x4.com/forum/showthread.php?t=632712&highlight=aussie+8.8

[Rulebreaker]

the aussie may be overstocked but a guy on pirate is selling an early 8.8 version new in box because he said it won't work since the cross pin is smaller.he may be wrong if so it would be a good deal-150$
http://www.pirate4x4.com/forum/showthread.php?t=632712&highlight=aussie+8.8

You were right when you said the pin sizes are different, The price difference is not because of the pin but because of an overstock. Mine is the later 8.8, but thanks for thinking of me. RB

[Rulebreaker]

The doubler is in but i have to fix one issue.
http://inlinethumb17.webshots.com/2384/2384481030040927262S500x500Q85.jpg
http://inlinethumb37.webshots.com/34596/2907191670040927262S500x500Q85.jpg
Gas tank clearance.
http://inlinethumb37.webshots.com/7588/2500719020040927262S500x500Q85.jpg
When I built the crossmember the Ranger half of it is closer to the DS frame rail than it would normally be because the Aero is wider than the Ranger, and because of this it doesn't clear the front drive shaft. I'll have to redesign my crossmember.
http://inlinethumb16.webshots.com/34511/2890041150040927262S500x500Q85.jpg
Here is a pic of the shifters. The one by the tranny shifter is the doubler shifter the Ebrake hole is now the Tcase shifter.
http://inlinethumb47.webshots.com/34286/2891492260040927262S500x500Q85.jpg
It looks like a B2 front shaft might work. Also anyone know the flange to flange distance for a 4 door Explorer rear drive shaft? I'm at 58 3/8 but i can move the rear axle a little if it would be close. RB

[rickcdewitt]

just out of curiousity what route did you go building the doubler?

[Rulebreaker]

just out of curiousity what route did you go building the doubler?

I used Todd's writeup, but my shaft broke so I did my shaft a little different the second time. RB

[Rulebreaker]

I took the rear axle shafts and my Explorer brake disc's to have some machine work done so I can finish the rear brakes. I also ordered an outer shaft and spring pad for the D44 from the graveyard so I can finish the front end. I've also decided to put a 3.5" block in the rear. This will put the rear about 1" higher than the front. Now I just need to sell some more of my B2 stuff so i can finish her. Everyone must be broke as I've had 3 buyers this week not show up. Christmas is just too expensive! Well Merry Christmas too all, I'll probably get back at her after Christmas. I can't wait to see her with the new front bumper, that will be the next big step. RB

[metalmacguyver]

I used Todd's writeup, but my shaft broke so I did my shaft a little different the second time. RB

what did you do different?

[86ford]

Once this ridiculously awesome build is done Ijust might have to drive my silly self up to MI to see this thing in person!!

i dont like 2 far from ya so i will split the gas if you go!

86

[Rulebreaker]

what did you do different?

If you machine the parts press them together and mig weld it, it will get small cracks in it and then shear. You need to take it to a professional welder :icon_welder: and have it tig welded and thrown in quenching oil. I didn't see it being done so there maybe more to it than i remember. The shaft had a blue tint to it that i do remember. Then NEVER run the doubler in low when the case is in high. thats how I broke mine. RB

[Rulebreaker]

Well I took a second stab at my Xmember. Will this baby hold a Doubler? RB
http://inlinethumb48.webshots.com/36847/2264231950040927262S500x500Q85.jpg
http://inlinethumb01.webshots.com/34752/2627472630040927262S500x500Q85.jpg
http://inlinethumb28.webshots.com/35291/2018184000040927262S500x500Q85.jpg
http://inlinethumb12.webshots.com/37579/2531205950040927262S500x500Q85.jpg
Instead of extending the flat portion I extended the hoop however this makes for 2 splices instead of one. RB

[Black'03LevelII]

i dont live 2 far from ya so i will split the gas if you go!

86

sounds like a plan to me.

[86ford]

i am up in rocky river so i am all for the trip!

that cross member looks like a bastard child from an erector set!

86

[Rulebreaker]

i am up in rocky river so i am all for the trip!

that cross member looks like a bastard child from an erector set!

86

I really dont care what it looks like, as long as it don't break. RB

[metalmacguyver]

beefy joint on that x member! :thumby:

[Rulebreaker]

beefy joint on that x member! :thumby:

It's in and holding them up!:yahoo: RB

[Danger FX4 Ranger]

I had one of the engineer's at Ford look into the steering pump dilemma, and he said he's 90% sure i need to change pumps. So hopefully one of my RBV pumps will bolt up and take the serpentine pulley. I'll know shortly. RB
Very creative and different. I wish I had an Aerostar that badass growing up, but for some reason mom just didn't want one. :sad: How in the hell did you ever explain what you are doing to an engineer at Ford? Once completed, I vote your van as truck of the month!

[Rulebreaker]

Very creative and different. I wish I had an Aerostar that badass growing up, but for some reason mom just didn't want one. :sad: How in the hell did you ever explain what you are doing to an engineer at Ford? Once completed, I vote your van as truck of the month!
All i asked is "can i run a conventional power steering box with a rack and pinion pump" The funny thing is they spent like 4 hours pondering this and were not 100% sure of there "NO" answer. Someone must know the exact differences but they were not able to answer it with certainty. They too want to see it when finished. RB

[Rulebreaker]

I ordered a pair of Aussie lockers for her today!:clapping::)
Now I'm broke again.:sad::sad:
RB

[86ford]

i mite be coming to raid whatever pile of b2 parts you have left since i got the motor back together today and havent had any issues.

86

[Rulebreaker]

I got the rotors back and drilled the new bolt pattern into them. How's it look?
http://inlinethumb25.webshots.com/36568/2701557290040927262S425x425Q85.jpg
http://inlinethumb64.webshots.com/36927/2822457800040927262S425x425Q85.jpg
RB

[Rulebreaker]

i mite be coming to raid whatever pile of b2 parts you have left since i got the motor back together today and havent had any issues.

86

You should by my D35 with the 4.11 gears and powertrax, I'm tired of tripping over it. RB

[86ford]

You should by my D35 with the 4.11 gears and powertrax, I'm tired of tripping over it. RB

its looking good for you. i got it out wheeling today and am starting to think the b2 mite hold up to my abuse.... all i need to do is find the cash!


86

[Rulebreaker]

I got to use my new 12 ton press tonight!:icon_thumby: I put in the 4.11 gears in the 8.8. I still need to run brake lines, build shock mounts, get it siting level and :icon_welder: on the spring perches. Hope to get that done tomorrow. Even then I still need to get my Aussie before I can finish the rear. RB

[Rulebreaker]

its looking good for you. i got it out wheeling today and am starting to think the b2 mite hold up to my abuse.... all i need to do is find the cash!


86
My B2 was tough. You cannot kill them! Even the Jeep guys said so. :D

[Black'03LevelII]

its looking good for you. i got it out wheeling today and am starting to think the b2 mite hold up to my abuse.... all i need to do is find the cash!


86

hmmm maybe we could start a communal truck like we talked about earlier today.

My B2 was tough. You cannot kill them! Even the Jeep guys said so. :D

I don't know about that, you haven't seen the way chuck drives his LOL!!

[Rulebreaker]

hmmm maybe we could start a communal truck like we talked about earlier today.



I don't know about that, you haven't seen the way chuck drives his LOL!!
This is me being gentle with mine.
http://inlinethumb02.webshots.com/21121/2531274990040927262S600x600Q85.jpg
This next photo is crappy but it's the only photo taken of my broncoII's first flight. The guy behind me said there was 12' between the top of the berm and the bottom of the Bronco. On the back side it drops off into a mud hole so i was 20+' in the air. This is what destroyed the D28.
http://inlinethumb57.webshots.com/36024/2964516980040927262S600x600Q85.jpg
http://inlinethumb57.webshots.com/38008/2485316500040927262S600x600Q85.jpg

[metalmacguyver]

so roll cage and 5 point harnesses for all of your daughters in the aerostar too?

[Rulebreaker]

so roll cage and 5 point harnesses for all of your daughters in the aerostar too?

Exocage for sure + I'll mix a little sanity into my driving. Since the "On her side" incident they don't trust me anymore:dunno: Funny thing is if i wouldn't have been arguing with one of them about wearing there seatbelt I probably wouldn't have ended up on my side. RB

[Black'03LevelII]

isn't that how it always works though?

[Rulebreaker]

I got it sitting level without using a lift block. I mixed in some leafs with more arch and added two. Then I installed the rear shocks. I also hooked up the speedo wiring but i'm not sure the rear ABS sensor on this axle will run the speedo or if I need to pull the one out of the Aero 8.8. Anyone think they know the answer??? The driveshaft is not done the one in the pic was just to set the pinion angle. So as soon as I get my Aussie I can button up the rear and I'll be done with the back.
http://inlinethumb46.webshots.com/37613/2755513570040927262S500x500Q85.jpg
http://inlinethumb32.webshots.com/36319/2995452360040927262S500x500Q85.jpg
http://inlinethumb01.webshots.com/38592/2235427800040927262S500x500Q85.jpg

[Black'03LevelII]

lookin' good man! can't wait till it's done so 86 and I can come up and check it out in person.

[metalmacguyver]

what made you mount the shocks like that? was it not going to have enough up travel if you tried to mount them vertical? or was it just convienience?

[Rulebreaker]

what made you mount the shocks like that? was it not going to have enough up travel if you tried to mount them vertical? or was it just convienience?

I dont like my shock mounts under the axle as they will be damaged, not a matter of if but when. Every Ford truck I've ever owned has had them on an angle so I decided there is no point in making a new upper mount. The shock collapsed is 18" and it's 18" from the top of the axle to the frame so I couldn't use them straight up and down anyway. RB

[pillen140]

thats awesome, looks like the boogey van, my mom used to have three different aerostars, every one die of trans problems., not lifted of course. about the door, what if you bring the track out from the body alittle more? or you could be the first with lambo doors on an aerostar

[Rulebreaker]

I just run my UPS tracking # and my Aussie's will be here tomorrow!:clapping::icon_thumby::cool::taunt::yaho o::woot::)

[Rulebreaker]

thats awesome, looks like the boogey van, my mom used to have three different aerostars, every one die of trans problems., not lifted of course. about the door, what if you bring the track out from the body alittle more? or you could be the first with lambo doors on an aerostar

The A4LD's are nothing to brag about but better than anything offered in a front wheel drive minivan, plus it's no big deal to change one. RB

[86ford]

hmmm maybe we could start a communal truck like we talked about earlier today.



I don't know about that, you haven't seen the way chuck drives his LOL!!

i have my fun and have other vehicles to drive so all i have to do is make it home and i am in the clear. james the b2 is already a community vehicle i dont give a shit who beats on it (within reason). i mean you cant be any harder on it than i am, well, and keep the tires on the ground.

86

[fordwheelinman]

What year is the rear axle, and what year is the aerostar? i can cross reference the two sensors at work one day in the wiring diagrams to see if the two function the same, then i can tell you whether or not the sensor may work.

[Rulebreaker]

What year is the rear axle, and what year is the aerostar? i can cross reference the two sensors at work one day in the wiring diagrams to see if the two function the same, then i can tell you whether or not the sensor may work.

It's a 93 Aerostar and the axle is a 91 F150 2WD 8.8. Thanks RB

[97ranger4x4]

I am also excited to see this completed. I think it would make a great truck of the month!

[Danger FX4 Ranger]

Funny thing is if i wouldn't have been arguing with one of them about wearing there seatbelt I probably wouldn't have ended up on my side. RB
The irony. :icon_rofl: :taunt:

[TeamExploder]

Wow...just read over this, my mom had just acquired a 93 Eddie Bauer 4X4 aerostar about 2 months ago, I joked with her bout interchanging t-cases with her explorer(so it'd have 4low) and lifting it for an off-road maching (it won't happen) but cool work with your aerostar project.

[Rulebreaker]

The irony. :icon_rofl: :taunt:

It gets better. So when we end up on our side she's in my lap. So i ask her if she's ok, then ask her if she had her seatbelt on and she says yes. Then I asked her if she had her seatbelt on how is it that she's in my lap. She must not have thought that one out very well, because she wasn't sure what to say. RB

[Rulebreaker]

I am also excited to see this completed. I think it would make a great truck of the month!
Thanks RB

[Rulebreaker]

Wow...just read over this, my mom had just acquired a 93 Eddie Bauer 4X4 aerostar about 2 months ago, I joked with her bout interchanging t-cases with her explorer(so it'd have 4low) and lifting it for an off-road maching (it won't happen) but cool work with your aerostar project.

Lifting a E4WD Aero would be tough if not almost impossible without a kit. I would never discourage someone from trying tho. RB

[Rulebreaker]

http://inlinethumb61.webshots.com/39228/2924265810040927262S500x500Q85.jpg

[metalmacguyver]

mmmmm...locker :drool:

[Rulebreaker]

I finished up the brakes on the rear axle tonight. The rubber hose on the axle wasn't long enough so I put one of these extention lines on it from autozone. http://www.therangerstation.com/tech_library/images/NewBrakeLinePieces.JPG
I also run new hard lines and had to buy new Caliper bolts as i had Rock rashed the old ones. Tomorrow night I'm building skid plates for the T case and gas tank. RB

[Rulebreaker]

The guy that's building my front bumper came over to take a look last night. We decided that because I can't really bring him my van and work on it at the same time that he would use the stock front bumper for a template so off it came.
Before
http://inlinethumb49.webshots.com/39408/2248128410040927262S500x500Q85.jpg
After
http://inlinethumb37.webshots.com/37284/2317458600040927262S500x500Q85.jpg

[stedal]

Nice Aero. Check out mine http://therangerstation.com/forums/showthread.php?t=8440

The side door trouble was fixed by making the link (the one in the back of the door) longer, so it can go over the fender flare. I will try to put in som pictures, i´m sure it easyier to understand them then my english:derisive:

[Rulebreaker]

Nice Aero. Check out mine http://therangerstation.com/forums/showthread.php?t=8440

The side door trouble was fixed by making the link (the one in the back of the door) longer, so it can go over the fender flare. I will try to put in som pictures, i´m sure it easyier to understand them then my english:derisive:

I'd like to see some underside pic's. Looks good and I hope to have the same rear suspension some day. RB

[Rulebreaker]

Just to give you an idea of what my new bumper will look like, here is a couple pic's of a bumper he built for another person that is very similar to what he's building me.
http://inlinethumb27.webshots.com/38682/2097813120040927262S425x425Q85.jpg
http://inlinethumb30.webshots.com/37405/2469089580040927262S425x425Q85.jpg

[TeamExploder]

Tough lookin bumper, wouldn't mind havin one of them on the ex's

[91exploreron37]

What does he charge for those?

[Rulebreaker]

What does he charge for those?

Depends on what you want but I'm guessing he get's around $500. I gave him $200 down but I'm not sure what I'll owe him when it's finished. He's been building them for quite some time and I've witnessed some serious jerking with no problems. He built the bumpers on the white Cherokee that was in last years real truck club challenge. The one that ended up on it's side. RB

[Loanranger]

Damn, that's a very nice bumper, the aero one is gonna look badass.

[Danger FX4 Ranger]

How much $$$$$$ have you invested so far?

[91exploreron37]

That is a nice bumper:drool:, does it have a winch mount? I might have to take a trip up there to have him make me one.

[Rulebreaker]

Damn, that's a very nice bumper, the aero one is gonna look badass.

I can't wait to see it finished, I'm getting so close i can taste it. I finished welding the sub frame tonight + added another attachment to the frame rail. I've got the skid plates all cut and they will be sent out to be bent to shape this week.RB

[Rulebreaker]

How much $$$$$$ have you invested so far?

I'm at $1150 right now. Keep in mind I've had allot given to me and I had allot of part's saved up for this. I still need to buy a rear bumper, exocage, steering tie rods, maybe some rims and some front end parts. I'd like to initially be under $1500. Time will tell. RB

[Rulebreaker]

That is a nice bumper:drool:, does it have a winch mount? I might have to take a trip up there to have him make me one.

Yes it does, I cannot wheel without my winch! RB

[Danger FX4 Ranger]

Wow, only $1150? Not much considering the amount of work and parts needed.

[Original_Ranger84]

thats awesome, looks like the boogey van, or you could be the first with lambo doors on an aerostar

Dude, No Way! You should paint it like the Boogy Van.:icon_idea:

Make the sliding doors open like an airplane.(with steps so when its on the ground you can get in like an airplane.) Also if you got stuck in a deep pond or something you could get some of those pull rafts for the door too (so you wouldn't have to wade through the mud/water.)

Nice Build so far.:clapping:

[Rulebreaker]

I'm all but finished with the brakes. All I had to do was weld the hose holder on the right front tire and mount the hose and i ran out of :icon_welder: wire.:annoyed: I'm picking up my skid plate tomorrow for the T case, so that will leave me with the gas tank skid plate to finish on the underside. I'm thinking about taking a few days off from the project. Maybe I'll get back at it Friday. RB

[Black Widow '90]

sweet truck rulebreaker, i see your from manton, i'm from petoskey:)

[Rulebreaker]

http://inlinethumb48.webshots.com/39919/2527138280040927262S425x425Q85.jpg
Skid row. RB

[Sunk]

Nice, looks beefy.

[metalmacguyver]

1/4 plate?

[Rulebreaker]

1/4 plate?

You got it! RB

[351ranger]

Are you planning on fixing the rocker panel you cut off? Very interesting build. I like turning things into 4 wheel drive that werent to begin with.

[Rulebreaker]

Are you planning on fixing the rocker panel you cut off? Very interesting build. I like turning things into 4 wheel drive that werent to begin with.

It's getting an exocage that will replace the rockers plus I'm going to make the rear wheel wells bigger and incorporate the rear bumper to make the back side of the well. RB

[Rulebreaker]

I got a set of rims for her today for $100. They are 15x8 white steel rims and they came with center caps and lug nuts. Tomorrow I'm going to get the tires for her. I'm looking to get a set of 35" claws for $200. I haven't seen them yet but from what I've been told they are in good shape. Can't kick a set of tires and rims for $300. Next week my goal is to finish the front axle so i can trailer it over to the bumper guy's house. RB

[Rulebreaker]

http://inlinethumb33.webshots.com/41248/2237484510040927262S425x425Q85.jpg
http://inlinethumb38.webshots.com/39653/2527045980040927262S425x425Q85.jpg
http://inlinethumb19.webshots.com/11858/2210835250040927262S425x425Q85.jpg

[Hardwareman]

Lookin good bro!

Good to see you'er staying on it. My bank account would'nt allow it right now.....lol




Allen

[Rulebreaker]

http://inlinethumb48.webshots.com/39919/2527138280040927262S425x425Q85.jpg
Skid row. RB

Part2
The top side is painted but not the bottom but you get the idea.
http://inlinethumb22.webshots.com/33365/2340414690040927262S425x425Q85.jpg
This is the B2 gas tank skid plate re bent to fit the aerostar.
http://inlinethumb47.webshots.com/26350/2529903820040927262S425x425Q85.jpg
Here is the piece that will connect the two.
http://inlinethumb44.webshots.com/26027/2883617130040927262S425x425Q85.jpg

[Rulebreaker]

Lookin good bro!

Good to see you'er staying on it. My bank account would'nt allow it right now.....lol




Allen

I've been very fortunate with this project. I'm feeding 7 mouths at home and have twins due in Feb, so i know all about building on a budget.I'm not an educated man so you get the idea as far as my income goes. This wouldn't be coming together without the grace of God and many people who have either given me stuff or given me deals on stuff. It's kinda like a community rig. I hope to finish it before the twins are born or it might get put on the back burner. So it's a wide open race! RB

[Rulebreaker]

After voting I pulled all the bearings out of the front end tonight. Everything was in bad shape. So tomorrow I'll be picking up Carrier and pinion bearings. I've already got spindle bearings and seals. Once I get them I should have everything I need to put the front axle together. Not bad considering I started with an empty housing. I'm starting to see the light at the end of the tunnel. RB

[Black'03LevelII]

sweet work man!! keep it up at this pace and I'll have to be taken a day off work to wander up that and check it out!

[Rulebreaker]

Being that my tires are used I thought it would be nice to have some fresh edges on them, so I took a auto glass cold knife and heated it, and the tire went under the knife. What ya think?
http://inlinethumb43.webshots.com/40682/2479838910040927262S425x425Q85.jpg
http://inlinethumb64.webshots.com/41535/2022912660040927262S425x425Q85.jpg
RB

[Sunk]

Cool, looks like those tires should have some good grip.

[Rulebreaker]

I finished the first tire. It took me 2 hours and a 1/4 bottle of MAP gas. Think it will pay off? I'm looking at 6+ hours to finish them. ????????????????????
http://inlinethumb26.webshots.com/39001/2676935430040927262S425x425Q85.jpg
http://inlinethumb51.webshots.com/41458/2155709010040927262S425x425Q85.jpg
http://inlinethumb50.webshots.com/20721/2167995930040927262S425x425Q85.jpg

[predator]

oooohhh have fun siping tires man....i siped a set of 40'' baja belteds.....12 hours later it still sucked.....

[Rulebreaker]

So all I needed were two bearings for the front pig but man they dont give that stuff away. Cheapest I could find locally was $60 something for 2 bearings. I ended up buying a National "KIT" for $75 that had all 4 bearings and some other crap in it. So I brought that home today and got started on it. Spent most my time cleaning out the crap that is packed into every crevice of the front axle. It was from a Mud truck so that's why I needed new bearings. Tomorrow I'm going to my local steel provider to see if I can find a tube to build my rear drive shaft out of. Hopefully by Sat night the drive train will be done. Then she'll go on the trailer and head to the bumper guy's house. RB

[predator]

is there anyone else that can barely wait to see action pics of this????


i know im not the only one.....great job rulebreaker, you give us lazy guys some motivation to go build something......

[TeamExploder]

Lol yeah I can't wait to see it go to work :)

[metalmacguyver]

im waiting with you guys too. :D

[Rulebreaker]

Well nothing has gone as planned this weekend but I'm still making progress. First the local steel provider don't have and cut off's the right size to build my rear shaft from. They don't even have a full stick of it. If they order me a 60" piece of it it will be $75. So I'm holding out right now for a better deal.Then I went to put the pinion in and remembered that my oil slings are junk and I have no yoke. Nobody around here carries the oil slings so i decided it was time to place an order with Jeff's Bronco Graveyard. I need front shocks so I decided last night to come up with a plan for that and get them ordered too. So last night I ordered the axle parts I needed and shocks. I got a set of Supperlift 3-4" lift shocks for a 78-79 Bronco. They are 22.9" extended and 13.9" collapsed. They have a stud on top and eyelet on bottom. This allowed me to use the stock Bronco and stock Aerostar shock mounts. I just had to Modify both a little. I've got the PS one done. Here is a pic. The shock is just to line everything up. Before you criticize the brake line is just temporary and will be replaced before she goes on the road.
http://inlinethumb04.webshots.com/39939/2181433220040927262S500x500Q85.jpg
Before pic.
http://inlinethumb21.webshots.com/40532/2558886040040927262S425x425Q85.jpg

[86ford]

that brakeline looks like something i would drive on the road! we will be meeting up with you for some wheeling this summer i hope!

86

[Rulebreaker]

that brakeline looks like something i would drive on the road! we will be meeting up with you for some wheeling this summer i hope!

86

Sounds like a plan. RB

[Rulebreaker]

Well I got quite a bit done today. Both shock mounts are finished. Put the diff cover on the 8.8 and painted it. Then I put a gallon of 80W90 in it and it's still not full so i'll be picking some more up. I filled the Tcase. I started to fill the tranny but ran out of 75W90. I filled the engine with oil and put on a new filter. I removed the old starter for auto and installed a manual starter. I primed and painted the sub frame and part of the gas tank skid plate and then ran out of paint. So being out of everything I was going to go to town but my truck won't start. First time in 6 years she hasn't started. I must have gotten some crappy Diesel fuel. She's plugged in now so we will see. Kinda goes along with everything else that's gone wrong. Anyone got a place Murffy can stay tonight so he'll leave me alone? RB

[Rulebreaker]

Well I figured out my glow plug relay was bad so i went to town to get a new one and while i was there I picked up some more oil and paint. So all the fluids are toped off except the antifreeze as there is no radiator yet and the front pig. I cleaned the spindles and put new bearings in them. I then put my axle shaves together. I then went through my lockout parts and threw a bunch of them in the parts washer to soak. I also knocked the studs out of the front hubs and threw the rotors away. I went threw my pile of rotors and decided they all need to go to the scrap yard. Tomorrow I'll clean the lockouts and then throw the hubs in the washer that way when my front pig parts show up this week I can rock N roll. I hope to have her on the trailer and too the Bumper guy Sat morning. I'll probably just spend the day there so I can drive it next week. Wont that be the bomb! RB

[Rulebreaker]

I picked up a pair of rotors. Wow are they cheap. >$20 each. I also have checked every place in town that sells steel or builds drive shafts for my drive shaft pipe with no luck. So a buddy of mine who works in Traverse City is going to check with Valley truck. If they don't have it I'm screwed. I cannot believe it's that hard to find. RB

[Black'03LevelII]

I picked up a pair of rotors. Wow are they cheap. >$20 each. I also have checked every place in town that sells steel or builds drive shafts for my drive shaft pipe with no luck. So a buddy of mine who works in Traverse City is going to check with Valley truck. If they don't have it I'm screwed. I cannot believe it's that hard to find. RB


try and find out if you have a Fleetpride close to you. If so try them, and if they can't help ya then you really are screwed.

ok just went their site and the closest fleetpride to you is in Toledo ohio, not sure how far of a drive that would be but I'm sure if the have something that they could ship it. Here's a number to call if you wanna try that: 800.333.3161 should be right to them Good luck man.

p.s. here is a linky (http://www.fleetpride.com/fp_p/branch.html) to the info page I found, as well as a linky (http://www.mapquest.com/maps/map.adp?country=US&addtohistory=&address=220+INDIANA+AVE&city=TOLEDO&state=OH&zipcode=43604&homesubmit=Get+Map) for the map, looks like they are right off of I-75.

[91exploreron37]

Can you just use a piece of regular pipe or does it have to be a certain kind? I have to redo my front driveshaft to work with my new manual t-case.

[Rulebreaker]

Valley truck only had 18" of what I need but were able to order me a 72" piece for $50. So I'll have that tomorrow. You metropolitan guy's don't know how good you got it when it comes to parts stores. My 4 wheeling buddy said when he lived in IL he had a local store that sold just bearings but had every bearing imaginable in stock. :drool::drool:
The Graveyard shipped my parts today so hopefully I'll have them by Friday. RB

[Rulebreaker]

Can you just use a piece of regular pipe or does it have to be a certain kind? I have to redo my front driveshaft to work with my new manual t-case.

Every driveshaft I've cut open has been regular pipe. I always thought it was something special or DOM but NOT. The local steel provider had tons of pipe for my front shaft. Are you needing to lengthen it? RB

[91exploreron37]

Yea people were telling me that its square on the inside or something. Well actually since I cant find a manual 1354 T-case anywhere I have to use a 1350 and the driveshaft that goes with it but its too long so I was going to cut the required amount out of the middle and then slide a small piece of pipe over the two halves and weld it on both sides. Do you think that is sufficient? I figured it doesnt have to balanced since im never in 4 wheel drive on the street.

[Rulebreaker]

Yea people were telling me that its square on the inside or something. Well actually since I cant find a manual 1354 T-case anywhere I have to use a 1350 and the driveshaft that goes with it but its too long so I was going to cut the required amount out of the middle and then slide a small piece of pipe over the two halves and weld it on both sides. Do you think that is sufficient? I figured it doesnt have to balanced since im never in 4 wheel drive on the street.

If you look where the tube meets the yoke you will see a weld. I would take a grinder and put a 1/16" cut off wheel in it and cut into the weld and threw the pipe. You can cut into the yoke a little with no harm. Then pull the yoke out and cut the pipe to length. Slide the yoke back in and re weld it. you may need to put a slit in the pipe in order to pull the yoke out. The yoke is only in the pipe only like a 1/2 inch.RB

[Loanranger]

Like RB said, it's really easy to shorten this way. What I did is carefully grind the weld smooth down to the surface of the yolk, then cut the weld with a cutoff wheel till you see a crack in the bottom of the grind. Once you're all the way around, smack it with a hammer and the yolk should fall right out.
If it's got a slipyoke, and you're shortening it, take your extra out of the end.
http://i157.photobucket.com/albums/t64/Dcdatsuns/reardrive.jpg

For lengthening, use the same procedure, and I used some DOM tube for the new piece, cost me $40 for the tube.

extended on top, stock on bottom.
http://i157.photobucket.com/albums/t64/Dcdatsuns/frontdrive.jpg

One important thing is to make sure your ends are in phase, or completely parallel to each other. If you have a semi flat floor in the garage, you can set them both on the floor flat and press it together. For a halfass balance job, I took and raised the front tires off the ground, put the transfercase in neutral, and bolted the driveline in before welding. This way I could spin the tires, and watch for any wobble. Just use a chunk of wood to smack the ends till it doesn't wobble, then tack it. Take the shaft out, put it on a couple blocks of wood, so you can roll it for the final weld, and you should be good to go.

[91exploreron37]

Thanks for all of your help thats looks like a better way than what I was originally going to do.

[Rulebreaker]

I got all my parts from the Graveyard and from Vally truck yesterday! I've got the shocks in and am working on the front axle now. RB
http://inlinethumb37.webshots.com/41700/2036054460040927262S425x425Q85.jpg

[Rulebreaker]

Man this front axle is fighting me every step of the way. I put the ring gear back on the carrier and then thought it would be easier to install the Aussie locker on the bench so I tried to install it and i couldn't get it in there. I had to remove the ring gear and then use a soft hammer just to get it in there. I was able to install the last one(My 75 Bronco) without even removing the carrier so i'm not sure why this one is so tight. The front pinion race went in like a virgin. Took me almost two hours to get that in. I've put every shim I've got for the pinion in and it's still just a tad tighter than I like. Then i went to install my axle shaft seals and they are too small. I didn't realize the 78 & 79 D44's took different seals and I must have told them the wrong year. So I'll get after her again Sat. RB

[Rulebreaker]

Man this front axle is fighting me every step of the way. I put the ring gear back on the carrier and then thought it would be easier to install the Aussie locker on the bench so I tried to install it and i couldn't get it in there. I had to remove the ring gear and then use a soft hammer just to get it in there. I was able to install the last one(My 75 Bronco) without even removing the carrier so i'm not sure why this one is so tight. The front pinion race went in like a virgin. Took me almost two hours to get that in. I've put every shim I've got for the pinion in and it's still just a tad tighter than I like. Then i went to install my axle shaft seals and they are too small. I didn't realize the 78 & 79 D44's took different seals and I must have told them the wrong year. So I'll get after her again Sat. RB
I had to order the seals so i'm going to start on the drive shafts Sat morning. Hopefully I'll have her mostly wrapped up Sat. RB

[Rulebreaker]

Drive shafts are done and in. RB
http://inlinethumb13.webshots.com/20364/2183610500040927262S425x425Q85.jpg
http://inlinethumb06.webshots.com/41029/2861723540040927262S425x425Q85.jpg
Do you think i need to move the exhaust up?
http://inlinethumb25.webshots.com/38168/2554259580040927262S425x425Q85.jpg
http://inlinethumb64.webshots.com/42495/2849430770040927262S425x425Q85.jpg
http://inlinethumb34.webshots.com/42337/2897681100040927262S425x425Q85.jpg
http://inlinethumb55.webshots.com/37110/2614420840040927262S425x425Q85.jpg

[Rulebreaker]

Front pig is in with the Aussie. RB
http://inlinethumb36.webshots.com/35235/2040516740040927262S425x425Q85.jpg
http://inlinethumb33.webshots.com/40736/2564327570040927262S425x425Q85.jpg

[Rulebreaker]

Anyone here know what I need to do to wire the TK4 to the A4LD wiring? I'm assuming there is a neutral start switch and reverse lights. RB
http://inlinethumb54.webshots.com/29557/2726737210040927262S425x425Q85.jpg

[Loanranger]

Hey this thing is really coming along, you'll be out on the trail in no time.
As for the wiring, I'm not sure about tieing the tk4 to the A4LD wiring, but when I put the 2.3 and tk4 in the LJ, I simplified the wiring quite a bit. All I did for the neutral start switch was to jump the two wires together. The main reason I did this was the switch stuck out too far, and I would have had to make a small box in the side of the trans tunnel for it. So I just took it out and put a plug in it. A bonus to doing it this way is if you are ever out on the trail and in a bad situation, you can creep the rig forward with the starter. I know it's not good for it, but in some dire emergencies, it may come in handy. The reverse lights, you may be better off running a new circuit, not sure. Something I haven't worried about on the LJ, as it's just a trail rig, and when it's coming at you backwards, that means it's in reverse.

[Rulebreaker]

Hey this thing is really coming along, you'll be out on the trail in no time.
As for the wiring, I'm not sure about tieing the tk4 to the A4LD wiring, but when I put the 2.3 and tk4 in the LJ, I simplified the wiring quite a bit. All I did for the neutral start switch was to jump the two wires together. The main reason I did this was the switch stuck out too far, and I would have had to make a small box in the side of the trans tunnel for it. So I just took it out and put a plug in it. A bonus to doing it this way is if you are ever out on the trail and in a bad situation, you can creep the rig forward with the starter. I know it's not good for it, but in some dire emergencies, it may come in handy. The reverse lights, you may be better off running a new circuit, not sure. Something I haven't worried about on the LJ, as it's just a trail rig, and when it's coming at you backwards, that means it's in reverse.

Ready or not I'm going wheeling with this thing in 2 weeks. I might walk home but that's ok. RB

[Rulebreaker]

I thought I would have the drivers side done last night but at 10 o'clock I broke the caliper bolt off flush. Why can't we get good American bolts anymore? I'm so tired of the China crap. I got the front pig cover on and the oil put in it. Hope fully I'll be loading her on the trailer in the next day or so and going to get my front bumper. RB

[fordwheelinman]

i feel your pain, i did the same exact thing on my 78. Kinda pissed me off a little bit.

[Rulebreaker]

Drivers side is done.
http://inlinethumb40.webshots.com/29479/2503701890040927262S500x500Q85.jpg
http://inlinethumb55.webshots.com/2038/2251767100040927262S500x500Q85.jpg
I need to do some fender trimming. Didn't Ford know I need room for 35" tires? RB

[Black'03LevelII]

ya know the closer it gets to being done the more ya want it done LOL!! I'm lookin forward to comin up and checking this beast out!

[Rulebreaker]

Front end is done. So I wanted to know if the exhaust and drive shaft will want to occupy the same space so---------------------------------------------
http://inlinethumb64.webshots.com/40127/2596912080040927262S425x425Q85.jpg
http://inlinethumb52.webshots.com/37619/2478117960040927262S425x425Q85.jpg
http://inlinethumb53.webshots.com/38644/2869181000040927262S425x425Q85.jpg
http://inlinethumb26.webshots.com/7513/2473429760040927262S425x425Q85.jpg
I had to stop because the rear wheel was up against the body. The rear definitely flexes more than the front but I knew this would be the case as my 75 Bronco is the same way. It's going on the trailer tomorrow night ( If it fit's) and headed to get a front bumper. RB

[Black'03LevelII]

Just got one question for ya. Why in the world didn't Ford offer it this way to begin with?? This thing rocks!!

[Rulebreaker]

ya know the closer it gets to being done the more ya want it done LOL!! I'm lookin forward to comin up and checking this beast out!

I talked my wife into the drivers seat (She's less than a month from delivering twins: God bless her heart) so I could finish bleeding the brakes. She says she's not driving it because it gives her a nose bleed. LOL I didn't figure she'd help me. Usually I get my 7 year old daughter to help me (Money usually helps) but she's in bed. RB

[Rulebreaker]

Just got one question for ya. Why in the world didn't Ford offer it this way to begin with?? This thing rocks!!
Darn bean counters tied up the engineers!
RB

[Black'03LevelII]

hmph, friggin jerks. I need to touch base with chuck (86ford) and see when he would want to go so we can start planning to come up and meet ya and see thing in ACTION! how would say mid late march work for you? think it'll be all done by then or should we aim for a little later?

[Rulebreaker]

When I take it for exhaust should I just run straight pipe or should I put a muffler under there? RB

[Rulebreaker]

hmph, friggin jerks. I need to touch base with chuck (86ford) and see when he would want to go so we can start planning to come up and meet ya and see thing in ACTION! how would say mid late march work for you? think it'll be all done by then or should we aim for a little later?

I've never owned a rig that was "DONE" so whenever it's done enough for you. You can come up whenever but I'd prefer it was at least 2 weeks after the twins are born and I'm guessing they will arrive some time in late Feb. I just wont be getting out much then. RB

[Black'03LevelII]

while if you can get away with it (inspections and neighbors) I say straight pipe it.

[Rulebreaker]

while if you can get away with it (inspections and neighbors) I say straight pipe it.

I don't have inspections or neighbors, so neither are a problem. RB

[metalmacguyver]

i want action pics!!!!

[Rulebreaker]

i want action pics!!!!

It's going on a run on Feb 9th so I'll have a ton of pic's soon. RB

[metalmacguyver]

sweet!

[Rulebreaker]

I decided to hang the radiator and drive it on the trailer. Good thing too cuz I need to move the radiator towards the passengers side as much as possible as the lower radiator hose is right on the power steering box. So the bumper will need some adjusting. I really need to find someone who can tell me what two wires need jumping so i can start it with the key. Darn neutral safety switch. The is one plug with 3 wires and one with like 6. ????????????????? The shifter is too far back too. I'm going to do some bending. I was able to drive it out without changing tires so that was nice. I think I had a 1/2 inch to spare.
[IMG]http://inlinethumb15.webshots.com/9806/2348393020040927262S500x500Q

[91exploreron37]

Its the one with like 6 wires. Ive forgotten which wires to jump, but when I first did mine I started jumping wires together one by one until it started. I can look in the shed for my old auto harness and see what two wires need to be jumped if you cant find them. But if I remember correctly they were the two biggest wires in the set and they were like red/pink stripe and red/with blue stripe?

[Rulebreaker]

Its the one with like 6 wires. Ive forgotten which wires to jump, but when I first did mine I started jumping wires together one by one until it started. I can look in the shed for my old auto harness and see what two wires need to be jumped if you cant find them. But if I remember correctly they were the two biggest wires in the set and they were like red/pink stripe and red/with blue stripe?

I've got the wires going to the tranny figured out now I just got to figure out what the wires on the TK4 do so i can wire them together.

[Rulebreaker]

It's at the bumper guy's house so it's out of my hands for a while. It's weird to go out in the garage and not have it there. It's been in my garage since March 27th last year. I called the exhaust guy and ordered my exhaust and I called and put insurance on it today. Tomorrow I'll title it. RB

[Rulebreaker]

I remembered I have a Ranger Chiltons manual so i looked in the wiring diagrams.Looks like neutral switch is w/bk and bk/w and reverse is bk/pk and p/o. So I should be able to wire the tranny up now. RB

[Rulebreaker]

If you want to see all 124 Build pic's now with the pictures having titles and captions I have updated my webshots Aero4x4 Album. Feel free to check them out. I'm also going to put together a list of all the RBV part's in this rig, as there are allot of them.RB

[86ford]

whats a good estimate of the distance from cleveland to your place? i am willing to adventure up there but i would really like to have a rig and some place to play while i am there! b2 is comming along well. i am also in search of cheap or free parts as usual!

86

[Rulebreaker]

whats a good estimate of the distance from cleveland to your place? i am willing to adventure up there but i would really like to have a rig and some place to play while i am there! b2 is comming along well. i am also in search of cheap or free parts as usual!

86

http://www.mapquest.com/directions/main.adp?go=1&do=nw&rmm=1&un=m&cl=EN&qq=1ADqpk24ofDMVtyZ%252bbsoOZux42YfaOr3KBOOsmw8j5Q 5PnX9WwhrrEHWAAZcjaZ5QpRVVmrk0zwX9R2kDtuaUiZ%252bu UuBzXLePZ8DgOGb3nWIbUR%252fSC%252fjzw%253d%253d&ct=NA&r=f&rsres=1&1y=US&1ffi=&1l=&1g=&1pl=&1v=&1n=&1pn=&1a=&1c=Cleveland&1s=OH&1z=&panelbtn=1&2y=US&2ffi=&2l=&2g=&2pl=&2v=&2n=&2pn=&2a=&2c=Manton&2s=mi&2z=
Mapquest puts you under 6 hours but I can get to Detroit in 3 so that seems high. As far as wheeling I have a rock course on the property (Go to my webshots page and click on the rock pit album)plus State land trails with the normal MI stuff. I'm sure we could have a good time. RB

[Bent Bolt]

Been keeping an eye on your build. Gonna be quite the rig when you're done. Can't wait to see it on the trail !!:icon_thumby:

[Rulebreaker]

I worked on the tranny wiring tonight with very little luck. I've got no power for the reverse lights. The fuse in the fuse block has no power. I wired the reverse lights up(at the tranny) guessing at which wires to use. The wire harness for the neutral safety was not plugged in the tranny as I thought it was so I just wired them together. So it will now start with the key but that's the only progress made there.
I got the exhaust finished. I decided to use a muffler as I figure I'll be drawing enough attention with this as it is.
I also installed the headlights,grill, and side markers. Starting to look like a van again.
Dave got the center section of the bumper welded up and we checked to make sure the winch would fit in it. We moved the radiator up and towards the passenger side trying to make room for the lower radiator hose. We then had to grind some of the plastic off the radiator tank to clear the bumper bracket and ground just a hair to much and I've got a water leak. So we called it a night. I'm going to pull the spare one out of my parts rig and then see if I can get this one repaired.
I didn't take my camera so you have to wait till I get her home before i post any more pic's. RB

[rickcdewitt]

sounds like you could possibly benefit from a junkyard search to give you ideas for a radiator.an e-fan should give you more room to move the radiator around also.your local radiator shop might be able to put different end tanks on a suitable core if all else fails too.

[stegomon]

dude...that is awsome

[OhShietitzMike]

hi i'm new to the forum n i just got done reading the entire thread n this is a sick project. i also can't wait to see it on the trail n good luck n congrats w/ the twins . . . mike

[86ford]

i hope the price of your b2 parts is comming down as time passes because i will be up to play this spring ot summer!

86

[Rulebreaker]

sounds like you could possibly benefit from a junkyard search to give you ideas for a radiator.an e-fan should give you more room to move the radiator around also.your local radiator shop might be able to put different end tanks on a suitable core if all else fails too.

I pulled the radiator out of the parts donor this morning and it was in bad shape but the tank was ok so I removed the tank and RTV'd it to my radiator. Don't know yet if it will work or if it will hold water. Spent most the day at Dave's house working on it. I put B2 mirrors on it. I used rivet nuts and stainless bolts, to attach them. I reshaped the tranny shifter and installed the shifter boots. I reinstalled the engine cover and put the dash back together. I also enlarged both drivers side wheel wells. I reinstalled the radiator overflow and windshield washer tank. If you think it was tight before you should see it with a power steering box and lines in the way. I had to remove the battery tray just to get it in there. I repaired the broken bolt that holds the battery while i had the tray out. Dave made allot of progress on the bumper too. It's all tacked together so you can see the final shape+ he bent and attached the stinger and the bars that protect the fenders and headlights. This van looks totally different with the bumper. Once everything was the way i liked it we pulled it back off and he will finish welding and grinding it tomorrow and possibly have it painted too. So you guys will have a pic soon. RB

[Rulebreaker]

dude...that is awsome

Thanks, RB

[Rulebreaker]

hi i'm new to the forum n i just got done reading the entire thread n this is a sick project. i also can't wait to see it on the trail n good luck n congrats w/ the twins . . . mike

Thanks! It's going on a trail run this Sat if all goes as planned. That is if the wife is not in labor.RB

[Black'03LevelII]

:icon_hornsup:when it is all said and this thing is gonna :buttkick:

[Rulebreaker]

i hope the price of your b2 parts is comming down as time passes because i will be up to play this spring ot summer!

86

I only have a couple things left, I cannot believe how fast the parts sold. I only put the parts on here and Greatlakes4x4 and they sold like hotcakes. Wish i had 50 move RBV's to part out. RB

[Rulebreaker]

I pulled the radiator out of the parts donor this morning and it was in bad shape but the tank was ok so I removed the tank and RTV'd it to my radiator. Don't know yet if it will work or if it will hold water. Spent most the day at Dave's house working on it. I put B2 mirrors on it. I used rivet nuts and stainless bolts, to attach them. I reshaped the tranny shifter and installed the shifter boots. I reinstalled the engine cover and put the dash back together. I also enlarged both drivers side wheel wells. I reinstalled the radiator overflow and windshield washer tank. If you think it was tight before you should see it with a power steering box and lines in the way. I had to remove the battery tray just to get it in there. I repaired the broken bolt that holds the battery while i had the tray out. Dave made allot of progress on the bumper too. It's all tacked together so you can see the final shape+ he bent and attached the stinger and the bars that protect the fenders and headlights. This van looks totally different with the bumper. Once everything was the way i liked it we pulled it back off and he will finish welding and grinding it tomorrow and possibly have it painted too. So you guys will have a pic soon. RB

Here are the pic's.
http://inlinethumb03.webshots.com/38146/2765945840040927262S425x425Q85.jpg
http://inlinethumb06.webshots.com/837/2616410230040927262S425x425Q85.jpg
http://inlinethumb14.webshots.com/35085/2759922330040927262S425x425Q85.jpg
http://inlinethumb03.webshots.com/18946/2022564490040927262S425x425Q85.jpg
http://inlinethumb22.webshots.com/30805/2219878810040927262S425x425Q85.jpg
http://inlinethumb23.webshots.com/25430/2031311010040927262S425x425Q85.jpg
http://inlinethumb10.webshots.com/1161/2524912080040927262S425x425Q85.jpg
http://inlinethumb64.webshots.com/34815/2350301950040927262S425x425Q85.jpg
The bumper is finished and primed. Dave was going to paint it yet tonight so hopefully we can install it tomorrow night. Won't be long. RB

[fordwheelinman]

pics no worky for me

[Sunk]

I see em, its looking good. Those emblems are sweet too!

[97ranger4x4]

yeh I do like that name, Broncostar. I almost think you should make that your name!

[Rulebreaker]

I drove it down the road tonight. It's freezing rain and i found out the wipers don't work, so one more thing to fix. The radiator seems to be holding. So drum roll! :clapping:
http://inlinethumb17.webshots.com/40528/2498747020040927262S600x600Q85.jpg
http://inlinethumb37.webshots.com/38244/2336847630040927262S600x600Q85.jpg

[Black'03LevelII]

nice protection/safety gear. as long as everything else is working good the wipers should only be minor set back/easy fix.

[Rulebreaker]

http://inlinethumb49.webshots.com/24496/2482342600040927262S600x600Q85.jpg
http://inlinethumb22.webshots.com/30421/2266019850040927262S600x600Q85.jpg
http://inlinethumb14.webshots.com/21837/2515891090040927262S600x600Q85.jpg
http://inlinethumb36.webshots.com/40995/2709518220040927262S600x600Q85.jpg
http://inlinethumb49.webshots.com/35888/2367414020040927262S600x600Q85.jpg
http://inlinethumb59.webshots.com/42362/2137155010040927262S600x600Q85.jpg

[Sunk]

Damn, that looks badass! Definetly comes together with the bumper on there.

[Sunk]

Oops, double post.

[Black'03LevelII]

hey RB are those tires on right? they almost look like the tread is goin the wrong way, might just be me though. either that is one bad @$$ looking rig. amazing how the bumper really finished it!! your buddy did a great job.

[97ranger4x4]

wow that thing has turned out pretty amazing!

[Loanranger]

:icon_hornsup: That thing fawkin rocks man. It's a great feeling going out and seeing it all together ain't it? That bumper turned out great. Very nice build. Now you just need some pics of it all flexed out with some mud on it.

[Hardwareman]

Wow!

GREAT JOB DUDE!

Just take a minute and step back and take it all in! It looks amazing from top to bottom. I wish I had skills to do that myself. Makes me want to take a welding class.

I cannot wait to see daytime pictures of it! The white steel wheels combined with that heavy duty winch bumper really sets it off and finishes it nicely.




Allen

[Sunk]

hey RB are those tires on right? they almost look like the tread is goin the wrong way, might just be me though. either that is one bad @$$ looking rig. amazing how the bumper really finished it!! your buddy did a great job.

Yeah I was wondering about that too.

[Rulebreaker]

hey RB are those tires on right? they almost look like the tread is goin the wrong way, might just be me though. either that is one bad @$$ looking rig. amazing how the bumper really finished it!! your buddy did a great job.

I put them on backwards. Cuz I can. RB:headbang:

[predator]

rulebreaker my hat is off to you:icon_welder:you have done something incredibly clean in a very short amount of time


well done man:icon_hornsup:


if only the i worked as hard as you do on my projects.....

[metalmacguyver]

all i can come up with is Wow!

[dirtsquirt]

looks real good, great work

[86ford]

I put them on backwards. Cuz I can. RB:headbang:

you know what that tells me, your a retard and dident figure it out till after you mounted them now your saying it was intentional! i am itching to go out wheeling with this thing you have built!

86

[OhShietitzMike]

impressive how that bumper tied everything together . . . n like everyone said it cleaned it up a lot . . . now what's your plans for the back bumper n sliding door ??

[Rulebreaker]

Thanks guy's! It's nice to have the support. If i were to post this on Pirate they would tear it apart. I'm going to try and build a back bumper myself because dave is booked out for weeks right now. If I shim out the door track a 1/4" I think it will open all the way as I can force it open the way it is. If I don't like the tires backwards all I have to do is rotate them left side to right and they will run the correct direction. I've got to work some bugs out of it next. RB

[86ford]

pirate has a bunch of assholes who in many cases have "all show no go" trucks.

86