ThatGuy in that Explorer

Never really thought about making a build thread but now all my posts are so scattered it's hard to find them. I'm thinking I'll give the cliff notes version here and add links to the specific threads.

I've had my Explorer one year now and what a transformation!! I started with a bone stock 1991 Explorer that I bought off of Craigslist for $400. It ran and drove the almost 1.5hrs home the night I bought it.
This is it in the yard where I bought it.



Soon after, I began a whirlwind Craigslist campaign to source the parts for my build. I had already planned to go SAS so I bought and sold parts to make extra cash and get what I needed. I went through about 12 different sets of tires, 3 sets of axles, 4 sets of wheels, and several misc. parts. I highly recommend doing this if you have the time and patience. I actually came out way ahead with cash in my pocket and a 44/9 combo and the wheels and tires that are on it for free.

In the meantime I found out that the James Duff shop is only about 12 miles from my house so I spent lots of time there talking to them about different mods. I asked about them doing the SAS for me and using it as a kit for the public. They had been working on different upgrades to some of the stuff they already sell but needed someone to test some stuff for them. I agreed to be the guinea pig if they would do my SAS.

I went wheeling in the Ex first. Took it to Harlan, KY last year for a Bronco event and followed the guys from Duff. All stock w/ no lift, 32" BFG A/Ts on stock Jeep wheels.



Then we had some planning issues and I didn't get to work on the Ex for a bit. I continued trading around and got a set of 35s that I wanted to run when I done the 6" TTB lift. Only problem was I traded the tires I had so I had to put the 35s on with no lift.



Had to drive it to the Duff shop like that. Easy on the bumps.

We then started on the first complete Explorer lift that they had done. It was the standard 6" lift you can buy from them with the exception of the new coil buckets and a new rear spring pack.
It took 2 days to put the lift on as there were only 2 of us working on it after hours.



When it was done, I was soooooo ready to drive it! It had a certain look to it that I really liked.





I was very impressed in the ride and drive of the big boat. It blew me away how the springs soaked up every bump in the road. I had been a Jeep Cherokee owner before and had a Rusty's lift kit on it that road like a log wagon compared to the Duff kit.

I had to wheel the thing so I went out to Windrock with Jimmy from TRS.



Trip didn't end so well. I blew both auto hubs.
Tore them apart and welded them to make them full-on drive flanges. Also welded up rear 8.8 at same time.
Wheeled a couple more trips but didn't think the flex was quite where I'd like.....

......so since I had the new coil buckets that would take either RBV coils or the much softer EB coils, I swapped coils.

Made these lower coil retainers to bolt on to the TTB.



Then it was out with the RBV coil



Twist the new EB coil in



And bolt it up



I used the 3.5" lift EB coils which matched up almost perfectly with the 6" lift I was running.

It was at that point where I ran into a major problem.





The softer EB coils were letting the suspension jack up because of the infamous TTB steering. The 6" RBV coils were around the 475 lbs/in rating whereas the 3.5" EB coils were only rated at 225 lbs/ in. I literally had to drive with ratchet straps holding the front end down.
I took it wheeling a few more times.










I didn't know what to do so I turned to TRS to find out. After a lengthly discussion, 4x4Junkie finally steered me in the right direction. I met up with Anthony who owns StoneCrusher Steering and we got to talking about the TTB setup. I gave him links that were provided to me by 4x4Junkie and we discussed the different steering setups that were offered. After a few weeks of bouncing ideas off each other, Anthony came up with the simplest solution. By putting both the pivot points of the steering right were the pivot points for the beams are the steering stays in phase and doesn't jack up on you.
This was the prototype version that we installed at his house.

It was at that point the Ex really came alive. It rode and drove great, flexed like all get out, and no funky steering problems.
Time to wheel again.




Even let my 5 yr old get some time in



Didn't take too much longer for me to finish up my trading. I ended up with a set of 39 Iroks that I wanted to put on the Ex. Time for the TTB lift to come off.

Bye, bye TTB---Hello bolt-on SAS

Few parting shots





Out with the old




In with the new




Just in case you've never seen an Explorer on a set of 39.5 Iroks on 17" wheels




The flex couldn't be measured cuz the tires were so damn big. Needed lots of sheetmetal cut.




Finally traded around for some 36" TSL/SX on beadslocks that made cutting minimal.



Could finally check the flex

All done and ready to go.



Then I was plagued with problems.
manual hubs had to be replaced
entire cooling system was replaced-water pump, radiator, thermostat, radiator cap, and a Taurus e-fan was put on.
brakes


So I had to sort through all of the problems one by one. I am, after all, a budget builder.
Got new hubs from JD
Replaced all the cooling crap and installed the Taurus e-fan. Wiring it up with my own little system that uses both the low and high side of the fan.
Lastly the brakes......I thought I'd never get them figured out. Ever since the 44/9 swap I had a spongy pedal. I chalked it up to the Explorer master cylinder not being big enough. I done a little research and found the F-150 master cylinder swap. Went and picked one up and hooked it up. Still had a spongy pedal. Finally found out the reason was because the lines were hooked up backwards (thanx cammeddrz)!

I've done a little wheeling.








And that's where I'm at right now.
Still trying to get the seat time in on this kit to see if it's going into production. I have lots more mods coming up and I will continue to document it here. This winter look for fuel cell relocated to back hatch area, front and rear bumpers, start of exo cage, full hydro steering. Next spring brings the new 4-link rear and possibly a drivetrain change.

its coming along nicely....where exactly is duff at?

I'm in Oak Ridge, Duff is in north Knoxville, TN.

That flex is sick. Wonder if my truck will ever do that??

This is my favorite Sploder ever. Definitely has my daddy. lol

That is exaclty the setup I want to do with mine. I jsut picked up a d44 this past weekend to swap in mine and want to try to get the duff sas stuff to put on mine like your also. Looks like it works great.

Got a couple questions for you. What did you do about hooking the driveshafts up? Did you have to get them shortened or anything and what joints did you end up having to use?

Can you get me a few pics of where the radius arms mount to the frame, the trans crossmember and the shock hoops please? Also see if you can get me on a list with duff to see if they will sell me another prototype track bar mount and shock hoops. lol

Cant wait to get the sas on mine. Im goign to be doing a doubler also so it should be a whole different beast.

Awesome Explorer man.

Great read, really glad you didn't sell/part it.

So....it was worth the 400 bucks? lol, looks great man. I really like it.

looks great man

Foxracin said:

Got a couple questions for you. What did you do about hooking the driveshafts up? Did you have to get them shortened or anything and what joints did you end up having to use?

Can you get me a few pics of where the radius arms mount to the frame, the trans crossmember and the shock hoops please?

Cant wait to get the sas on mine. Im goign to be doing a doubler also so it should be a whole different beast.

Awesome Explorer man.

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The front driveshaft had to be shortened by 1.5". I just cut the end of the shaft where the splines were and took 1.5" out and rewelded the tube. It then bolted right up. The rear shaft had to be lengthened by about 2.5"-3". I cut the slip yoke and resleeved it adding the length to it. I also had to use a bastard, cross, conversion, out of square, I've heard it called many things, joint for the rear.

Great read, really glad you didn't sell/part it.

Click to expand...

Yeah me too. I would've loved to have bought the house but I knew it wouldn't be on the market long. Now I can spend more money on this.

So....it was worth the 400 bucks? lol, looks great man. I really like it.

Click to expand...

It was. I've been beating on it for a year and no real major problems. I've got less than $2K total in it and I can take it just about any place I want. I've daily drove it off and on and wheeled the snot out of it. It rides great, is comfortable, and I can fit my whole family in it no problems. I've got A/C for the summer and heat in the winter. I done my fair share of open top wheeling and now it's all about comfort.