Giro Disc Posted August 23, 2011 Share Posted August 23, 2011 Hello, for those that have seen my other projects this is what I would call a medium undertaking. For those that haven’t, I hope this thread entertains you and maybe inspires you to undertake any project you have been putting off because you just can’t pull the trigger on it for fear of failure. Some of you may think this project is one of the best things you have ever seen. Others may think I am an idiot and I am wasting my time and money. In the end I hope you all enjoy. So about a year ago I bought a 97 Explorer from the Wife of my boss. It paid 500.00 for it and it runs and shifts like a top. 113K miles V6 RWD. I bought it to use in the winter months so I could garage my other car. Bought some new wheels, and tires for it and did a torsion twist on it to get the front end up a bit. I have never worked on an off road type vehicle before. All my past projects have been street cars with lots of HP so I was excited to dive into a new world. I started by making some steal bumpers, pre-runner style light bar, and a luggage rack with snowboard attachments. I have always wanted to build a pre-runner style truck. http://i186.photobucket.com/albums/x223/badwagon/Exploder/1113001550.jpg http://i186.photobucket.com/albums/x223/badwagon/Exploder/1113001550a.jpg http://i186.photobucket.com/albums/x223/badwagon/Exploder/xploder01.jpg Anyways… a year has past and one bad bearing and blown shocks have taken there toll on the suspension so I have decided to upgrade. I wanted to make a truck that had a lot of suspension travel and ground clearance. I didn’t want to lift it needlessly unless it was going to increase travel. However I also don’t need any heavy duty long travel pre-runner style kits because I am never going to jump dunes, or run at 70+ in the dessert, but I do want to go play in the dirt and if I am going to keep up with the 4wd guys then I am going to need momentum… So I have come up with what I think will be the best setup for me. It’s going to be a front long travel kit that utilizes the OE style torsion/ shock setup. This entire setup costs less then any long travel coilover kit w/o the coilovers. Total budget for this is about 2500.00 w/ tires. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension01.jpg Here is the parts list: 3” lift spindles Adjustable Upper Control Arms OE Lower Control Rods OE Inner/ Outer Tie Rods New Bearings Front OE Spec Universal Fox Racing Shocks Rear 2” Spacers Not Pictured: Type “1” Stiff Torsion Bars 305/70/16 Goodyear Duratrac Tires New Front Calipers New Front Rotors New Front Pads Spindles: I got these from Air Bag It. They are an all new heavy duty cast piece that they look great. Major plus points is the spindle itself un-bolts from the knuckle (OE is all one piece). The spindle itself also uses a stronger outer bearing from the F150, retains Stock Brakes, and ABS sensor. Also being a lift spindle it drops the spindle for instantly 3” of added ground clearance. Upper Control Arms: Also came from Air Bag It. These pieces are nice. They have a grease able ball joint and polly bushings on the inside. They are adjustable for easy camber/ caster adjustment and the best part is that they are made from bent steal tubing. (more on why later) Shocks: Fox 2.0 Performance universal shocks. After a bunch of research I opted for these over any Explorer specific parts because they are more heavy duty and the mounting points allow for a much wider range of shocks if I want to upgrade even further in the future. Almost identical to the OE shocks for extended and compressed length and custom valved for the type of driving I want to do. OE Parts: All Aftermarket with upgraded joints and bushings based on what I could find on the internet for quality parts. I could have just reused the original Lower control arms but getting new ones made it so I could do the fabrication and continue to drive the truck for less down time. Spacers: $60.00 of ebay with lifetime warranty. These are for the rear to space the rear wheels out to help with stability. Okay so on with project description: Using these parts I am going to cut and extend the Inner Tie rod, Lower, and Upper Control arms 8” to make a wide track, long travel suspension kit. By extending the arms I should have OE ride quality and an additional 8” of ground clearance (9.5” overall with the new tires) with an additional 4-5” of travel. I’ll get 16” of added wheel track for better stability (18” overall with new tires). The Lower Control arms will be cut and then extended with thick gauge sheet metal. Then reinforced I beam ribbing on the inside it should make for a much stronger then OE piece. Also a new shock mount will be added to fit the new shock. The Upper Shock mounts will be cut off and a new custom piece will be made and welded to the frame rail The Upper Control arms and Inner Tie Rods will be cut and extended by welded a solid rod to the cut pieces and then sleeved using a piece of tubing that is cut in half. The first half will be seam welded to the original and new rod and then the other half will be welded to other half. This should make for a strong durable extension. I have started with the lower control arms which are going to require the most work. First I cut them in half: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension02.jpg Then I welded two 4” wide pieces of steal together to get the desired 8” of extension and then welded them to the cut OE pieces. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension03.jpg Then a 3” wide piece in the rear and a 2” wide piece on the front for the side walls. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension04.jpg Tomorrow I hope to have pics of the finished control arms so more to come. Once the pieces are finished the truck will come in and they will be installed. From there I can check the ride height so I can figure out how much I need to lift the rear. Also new fenders will need to be made to work with the wider stance and larger tires so ones the suspension is finished I’ll be fabing those out of sheet metal as well. And finally to finish things off the truck will be getting a couple updates to the bumpers, some additional plating to the doors for bashing, custom running boards, and some custom mesh covered window frames in case 2012 brings about a zombie apocalypse… LOL But seriously if it does happen a zombie proof vehicle will be in high demand… I hope you have enjoyed what I had to offer so far. Johann @ Girodisc Link to comment Share on other sites More sharing options...
BDII Posted August 23, 2011 Share Posted August 23, 2011 not the platform I would have chosen, nevertheless, subscribe. Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
BAC5.2 Posted August 23, 2011 Share Posted August 23, 2011 This will definitely be interesting. Being 2WD does give you some flexibility that you wouldn't otherwise have. [URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard Link to comment Share on other sites More sharing options...
Giro Disc Posted August 23, 2011 Author Share Posted August 23, 2011 Yeah I mean sure I could have done it to a ranger or Toyota pickup, or a forester (my true dream). But yeah I figure I only paid 500.00 for the truck. It runs great and this setup I am building can be swapped onto another one if this one dies and I part it out. Ether way if I sell the truck whole I will make profit or if it blows up and I part it out I should be able to make all my money back if not a bit of profit for selling a unique suspension kit. This model of explorer seems to be the most trouble free of this gen and it was going to cost almost the same to just replace all the suspension parts that were shot for OE anyways so I might as well pimp it out. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Giro Disc Posted August 24, 2011 Author Share Posted August 24, 2011 Didn't get any work done last night. Put a new muffler on the GFs GC8 and tinkered spent some time looking over the rear of the exploder after I pulled the wheels off. New tires going on today. Going from BF Goodridge Mud-Terrains 31x10.5x16 to Goodyear Duratrac 33x12.5x16. Should be a nice stable pad, better in the snow and much much quieter. I am hoping to get some more work done to the A-arms tonight but I have to do some work to the Legacy because I am leaving for WCSS on Friday. Johann @ Girodisc Link to comment Share on other sites More sharing options...
BDII Posted August 24, 2011 Share Posted August 24, 2011 drum or rear discs? too lazy to re-read Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
rtbrjason Posted August 24, 2011 Share Posted August 24, 2011 Nice ride. This was a pretty sweet gen for this vehicle. I had a 98 Eddie Bauer with the 5.0 and really regret selling it. I would pick up another one in a heart beat as a second vehicle.. Link to comment Share on other sites More sharing options...
Giro Disc Posted August 24, 2011 Author Share Posted August 24, 2011 Rear disc. I replaced the Rear Rotors and calipers already. I had the front at the same time but I wanted till I got the new Spindles because I didn't want to buy another set of bearings. I think I found what i am going to do in the rear as well. Found some 4" lift leaf springs, and if I need to go higher I will do a longer rear shackle and then lower the front spring perch and pump stop to drop the whole assembly. I need to get a drive shaft spacer too I think as well. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Giro Disc Posted August 24, 2011 Author Share Posted August 24, 2011 So originally I thought I was going to have to modify a set of stock lines to lengthen them but I found some online that are 8" longer for lifted trucks that are SS and will work perfectly. Our supplier couldn't do them so this is perfect. Ordered up the leaf springs as well. Only thing that's still is unknown is weather or not I have to extend the driveshaft. Should have this truck draped up by the 10th so I can jump on to the Subreal Atom Project... Johann @ Girodisc Link to comment Share on other sites More sharing options...
BDII Posted August 24, 2011 Share Posted August 24, 2011 auto or manual? Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Giro Disc Posted August 25, 2011 Author Share Posted August 25, 2011 Auto. Got the new tires on there. Man O man what a difference! Smoother quieter ride and the truck looks a lot more off road worthy. WCSS starts tomorrow so no updates till next week. Johann @ Girodisc Link to comment Share on other sites More sharing options...
thestratomaster Posted August 29, 2011 Share Posted August 29, 2011 subscribed Link to comment Share on other sites More sharing options...
Giro Disc Posted September 6, 2011 Author Share Posted September 6, 2011 Okay so I managed to get all my other stuff done so I can get some time to work on the xploder. I finished boxing in the LCAs. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension05.jpg Then I took one and started doing all the bracing un the underside. I ended up running our of metal before I could finish so I am going to get more so I can finish the one and get the other one done as well so I can put the finish them off the top and bottom caps. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension06.jpg So with all the work I could do to those done I decided to get the Tie Rods out of the way. Cut them and make the extension pieces http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension07.jpg Welded them together: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension08.jpg Made the Sleeves: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension09.jpg Then welded it all together. It looks nice and stout. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension10.jpg I was going to start on the UCAs but I think I am going to need to fab them on the truck because they don't seem be the same on ether side and I worry that they might need some adjustment so I can going to mount them and then extend them. Finish welding them. Double check their fit, and then cut the mounts on the rail so I can redo them. That's all for now. Johann @ Girodisc Link to comment Share on other sites More sharing options...
DocHolladay23 Posted September 6, 2011 Share Posted September 6, 2011 Subscribe! [sIGPIC][/sIGPIC] You want stickers? Hit me up here!!! You want a shirt? Hit me up here!!! Link to comment Share on other sites More sharing options...
Giro Disc Posted September 6, 2011 Author Share Posted September 6, 2011 Oh I also forgot to add that the torsion setup isn't going to work like I originally thought. The extension is going to put too much leverage on the torsion bars so I am going to keep the shocks I have and use them in tandem with a set of FOX coilovers. I am also going to make new perches for the Upper control arms and shocks and do some heavy duty strengthening of the front suspension setup since I am doing a coilover I might as well build the truck for some added strength so I can do even more with it. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Giro Disc Posted September 8, 2011 Author Share Posted September 8, 2011 Got another update. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension11.jpg Finished up the bracing on the LCAs and replicated it to the other side. Got the first lower cap drawn out so I'll cut it and weld it up tonight. I am going to try and make a big push to finish the LCAs completely tonight. Also after a long wait my coilovers are here. Looks like they set me up with some King 650lbs springs so that will be a good starting point. I will make the upper and lower mounting brackets for these but wait to weld them on till after the arms are done so I can make sure they are put in the right position. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension13.jpg Also I found out the 4" lift leaf springs I ordered are back ordered till end of Oct so I canceled them and am going with a spring over axle kit. Should give me way more ground clearance since it will take some of the snag points from the suspension and move them up. I might need to get a helper spring to increase the rear rate a bit but I can do that after initial testing of the front suspension components is finished. A spring over axle kit is around 5-6" lift instead of the 4" I was going to get with the leafs but with the front going a minimum of 6" it should still be okay. I am hoping for 8" in the front so this should still work. More pics tomorrow of hopefully finished LCAs and coilover/ shock mounts. Johann @ Girodisc Link to comment Share on other sites More sharing options...
2.5gtbx_44 Posted September 9, 2011 Share Posted September 9, 2011 subscribed Link to comment Share on other sites More sharing options...
Giro Disc Posted September 12, 2011 Author Share Posted September 12, 2011 So fortune cam my way and I bought a car of my friend that later this winter is going to be turned into a dedicated auto x/ track car. However this made it so I could get the exploder in the shop and start getting stuff done while I drive my new project. Got one side of the stock stuff off and it was actually really easy. No rust on the truck what so ever. Got the Lower control arms on and the spindles and then checked to make sure they fit because they were a bit funny looking. Made a jig off the stock arms and welded in the extension rods that I slipped inside the cut tubes. http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension14.jpg http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension15.jpg So with it all together I could finally start looking at measurements to double check and make sure everything was going to work. Angle of movement on the arms is same as stock but I am getting an additional 9" of lift/ ground clearance and my travel increased from about 6" to 10.5 with the arm stopping at the original bump stop. After it was all set in I used the shocks I originally purchased to go with the torsion idea to set the shock position. I made some standard thick gauge tabs for the bottom and some more elaborate upper mounts that were fitted inside of the stock shocks cup. The to pieces were welded all the way inside to make basically to big gussets to strengthen the original mount and are also being welded into the rail as well as getting boxed in. (Pics of that later this week) So here is the shock fully extended: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension17.jpg And resting on the bump stop: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension16.jpg As you can see I have about an inch left in the shock with is perfect because it should even touch the shocks bump stop even with the body bump stop flattened out. But it looks like on the wheel its another 1 3/4" if the body bump stop was flattened out. So the coilover was about 3/4" longer then the then shock and the spring was a 14" so I can get a bit of pre-load on without loosing any lift. With the coilover set and just jacking the arm up at the spindle it lifts the truck off the jack stand with 1.5" of compression so with minimal pre-load it will have about 2" of droop. Once everything is finished I will get it on the ground and take it for a drive to see how it drives. If its to soft I can add more pre-load and if its still softer then I want I am considering throwing the torsion bars back in to help. Since alone that can't hold the weight and the arms angles are the same I could use them as a helper which will require less pre-loading on the coilover and allow for easier left to right adjustment. Time will tell. Here is a pic of everything lightly installed: http://i186.photobucket.com/albums/x223/badwagon/Exploder/XploderSuspension18.jpg So with the driver's side pretty much done I will be finished welding the last couple pieces onto the LCAs. I'll get the UCA all welded up and then its on the beefing up the frame rail and x-member. I am hoping by the end of the week I should have both sides installed for good and painted and the x-member all done. I will be gone this weekend so next Monday I will get the bearings, rotors and brakes on so I can put the truck on its own weight and give the system its first test. Once its dialed in to the way I like it I will do the SOA conversion to the rear and made the fender flares. More to come! Johann @ Girodisc Link to comment Share on other sites More sharing options...
That Guy 2-1 Posted September 12, 2011 Share Posted September 12, 2011 Subbed!! Link to comment Share on other sites More sharing options...
BAC5.2 Posted September 12, 2011 Share Posted September 12, 2011 Adding preload won't make it any stiffer. [URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard Link to comment Share on other sites More sharing options...
Giro Disc Posted September 12, 2011 Author Share Posted September 12, 2011 Right it will just give me height. I wrote that wrong. The torsion bar is progressive so adding them in tandem might be better then just getting a stiffer spring. Johann @ Girodisc Link to comment Share on other sites More sharing options...
BAC5.2 Posted September 12, 2011 Share Posted September 12, 2011 I think you are right about adding the torsion bars. Excited to see it on the ground! [URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard Link to comment Share on other sites More sharing options...
Giro Disc Posted September 12, 2011 Author Share Posted September 12, 2011 Me too. I will have 27" of front ground clearance. Its going to look insane! Brake Lines are coming in today so I am going to try and get the one side finished and install by tomorrow night so I can start on the other side. Johann @ Girodisc Link to comment Share on other sites More sharing options...
schnacko23 Posted September 12, 2011 Share Posted September 12, 2011 Subscribing just because it is so ridiculous it has become awesome! Link to comment Share on other sites More sharing options...
OutbackXT05 Posted September 13, 2011 Share Posted September 13, 2011 Subscribing. I wanna see how this goes. Looking quite interesting so far Link to comment Share on other sites More sharing options...
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