1999 Explorer Sport SAS

griz700rocket · Feb 5, 2015

I'm starting a build thread mostly so I can keep track of where I am at on this build. Here's the project vehicle as it sits currently. Spring over axle in back with shorter shackles, full coil over conversion in front. Aussie locker in back and lock-right in front.

I haven't made up my mind for sure if I want to go full width or not. I picked up a narrow front LP disk braked D44, lift coils, lockouts and some other spare parts from PlumCrazy (thanks again for hooking me up with this for a great price) but I also bought a full width front HP disk braked D44 with a matching 9in with disk brake conversion.

I've also picked up 5 used 35x12.50-17 BFG KM2s with a set of dodge rims for the large backspacing to keep it somewhat narrow if I do go full width axles. I checked and the local junk yard has a transfer case from a 96 ranger and a IFS toyota steering box that I plan on picking up.

I currently have a couple other projects in the shop so this is going to have to wait at least another week to clear some room out. If anyone is interested the other projects include an IH 400 Diesel that Dad and I are swapping front ends, adding a 1 wire alternator, rewiring and just general TLC. A 2003 kodiak 400 with a ton of miles that I'm going completely through for a neighbor and a 450 rhino that the same guy just bought that hopefully doesn't need too much.

griz700rocket · Feb 5, 2015

And since everyone loves pictures here's a few over the couple years I've had it.

Ghetto lean and reverse rake when I bought it.

Spring over and Torsion Twist.

My friend stuck, which eventually got me stuck and dad on a tractor stuck before we went and got a big tractor to pull us all out.

First time stuck.

Coil overs.

Non-impressive flex from coil overs.

Descent flex from spring over.

Custom bumper my welder friend and I made.

bobbywalter · Feb 5, 2015

Rowdy Fitzgerald · Feb 5, 2015

I'm diggin that bumper! It looks damn good!
I might just have to borrow the design if you don't mind.

Sent from my iPhone using Tapatalk

griz700rocket · Feb 6, 2015

Have at it Rowdy. My friend and I have built at least 10 bumpers of a design similar to that. I haven't taken many pictures but here's a few progress pics.

Grizzly 450 bumper, replaces all the stock plastic parts

Duramax bumper minus the bedliner we paint them with

Unfinished ambulance bumper, we had to rent a uhaul because they couldn't let have have the ambulance to use to build it on. Finished it had a single pipe ran across in front of the headlights and two in front of the grill

MoonKnight13 · Feb 6, 2015

Seriously, Yall take orders? I need a front bumper for a 91 Ranger 4wd.

griz700rocket · Feb 9, 2015

If you were close by I could arrange that. They aren't cheap though. A lot of man hours goes into them as they are completely custom built.

griz700rocket · Feb 9, 2015

I picked up a 79 f150 steering box with the axles I purchased for this swap. I'm reading up on converting this box to reverse rotation so the pitman arm will face toward the rear. Does anyone have any experience with this? I was planning on a yota IFS box but I'd rather stick with ford parts if I can.

bobbywalter · Feb 9, 2015

yeah, iirc the ranger input will reverse it. or was that a crown vic input? :icon_confused:

currently i am set up forward mount because i used a ginormous radiator. otherwise i would have used a 2wd chevy box. the 2wd chevy box works pretty goo too. especially if you want ram assist. i used the offset frame mount from a dodge truck application to use them boxes in the past.

the big ford box works pretty good though.

griz700rocket · Feb 18, 2015

Did a little offroading last weekend. Most likely the last time I'll wheel it before it goes under the knife.

Also did some mock up with the dodge rims after I enlarged the center bore to clear the lockout/hubs.

As you can see the tires are rubbing the radius arm slightly. I'm hoping to angle them in enough to not rub when I get the D44 under the explorer.

griz700rocket · Feb 23, 2015

With the bad/cold weather I decided to hold off another week before tearing it down so I got another day of wheeling in.

Stuck.......slowed down to avoid a small log and ended up like this

Got a little cold on the drive home that night.

Put the ole girl to work. You can't see it but there's a trailer on behind that I used to haul the bail of hay seen in the background. Handled it better than I thought with the crappy mono-leaf springs in the back.

Then I got a chance to bedline the rims I'm using after the SAS.

Before

Scuffed with wire wheel

After

Note that it peeled off a little around the outside from when the tires were mounted. I let it dry for two days but if I was doing it again I would give it at least a week.

griz700rocket · Apr 6, 2015

Teaser pic, sorry for the quality.

PlumCrazy · Apr 6, 2015

Went full width I assume?

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griz700rocket · Apr 6, 2015

Yeah, ended up getting an awesome deal on fully built 79 f150 axles. If you need any of the stuff you sold me just let me know.

PlumCrazy · Apr 6, 2015

Lol. I don't think so. I'm pretty much set on my D44 parts. You might still be done before me.haha.

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1999 Explorer Sport SAS

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