A few updates and question:
I remounted the radiator to allow use of the stock fan and built a support for the bottom of the radiator and welded it to the frame.
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I also got the shifter in place and discovered that it does not hit the dash although it is close. I will probably still bend it back a bit and shorten is by about 4 inches.
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The upper radiator hose is a stock Explorer and the lower is a flex hose. I'm still experimenting with different air cleaner/MAF/intake hose configurations.
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Now for the question--I burned up two starters and I'm not sure why. The original was the one on the F150 I got the trans, flywheel, etc. from, so it was the right starter. After many cranking attempts I finally got the ignition sparking and she started up. I shut it down to do some video and the starter would not turn on the next try. I took it out and got it tested and it was locked up and smelled like it burned. I got another today and checked to make sure it was the correct starter. Installed it, cranked and started right up. After the engine was running a couple minutes I got out to look around for issues and the starter had a small flame on the rubber insulation farthest away from the engine. Upon inspection I found that the teeth of the starter are just barely contacting the flywheel when they should not be.
Do I have start/run voltage to the starter and it is running all that time? I could not hear any of the grinding noises typical of a starter running when the engine is running. Is the solenoid activated and keeping the stater gear engaged? I'm baffled and maybe just a little "wiring dyslexic". Any help would be appreciated.