Dana 60 SAS w/2.5 air shocks

[King7765]

Per order of White Rhino and our PM conversations I'm starting my build thread.

Here is just some misc info of the truck
-1994 Ranger
-Extended Cab
-4.0L V6
-AL4D auto
-electric t-case

Before I decided to swap in the Dana 60 this is what I had under the truck...
-Dana 35 TTB w/4.56 and lock-right
-Currie 9inch w/4.56 and detroit (a lot more to it then just this)
-8inch coil lift from skyjacker
-3 inch body lift

I originally was going to use a Dana 44 fullwidth I had at the shop and sell the 78' HP Dana 60 to fund the Dana 44 SAS. But I soon realized that the 175 bucks I paid for the Dana 60 was never gonna present itself again, I decided to stay with the Dana 60.

My plans for this swap are as follows.
-78 High Pinion Dana 60
-3/4 ton brake conversion to keep my 37x13.5x15 Pitbull Rockers
-2.5 Fox air shocks
-3 or 4 link front suspension
-high steer arms
-ARB locker
-4.56 gear ratio
-possibly hydro assist (if i have ANY money left)

Here is some pics of the TTB...

[King7765]

Here is some pictures of the TTB stripped out...

[King7765]

Here the Dana 44 I was gonna use....

[King7765]

Here is the Dana 60 I decided to keep...

[WHITE RHINO]

looking good man have you decided on the link set up yet? what you doing in the rear? are you gonna still run that 9? what spline is it?

[King7765]

I have a lot more info to post up here. I've been running a four link calc and I'll be posting my numbers and info on that soon.

The 9inch has 31 spline alloy axles so that should hold up till I get a 14 bolt from a van.

Gimmie a few minutes I have a lot more pics coming tonight

[King7765]

Here is the Dana 60 all cleaned up with the blackbird customs 3/4 ton brake conversion, new cragar 15x10 rims and my 37inch PitBull Rockers

[WHITE RHINO]

right on how wide is the 9" also

[King7765]

When I got the 9inch built I got it to match the width of a factory Ford 8.8... If I knew I was gonna SAS the truck I would have ordered it full width. Oh well, I'll swap it into my 2wd 2002 ford ranger when i get the 14bolt.

[King7765]

Here is the axle under the truck... and stuffed into my small garage....

[King7765]

I wanted to use either a 4 link or a 3 link w/panhard bar. So either way I needed to box in the frame and possibly cut out the engine X-member.

I had a lot of "stuff" inside the drivers side frame that had to go. The fuel filter was there along with the fuel supply, return and vent. The brake lines where in there and also the antilock brake control was in there. ALL HAD TO GO...

[King7765]

To box in the frame I used that card board paper that students use for school projects, you know....that white thick card board...

Anyway, I traced out the frame pattern onto the card board and then I used a compass set to the thickness of the frame and traced around the pencil marks on the card board. That gave me a final piece of paper that fit inside the frame...

Then I transfered it to 10 gauge plate steel. The guy at the steel yard said 10 gauge is slightly thicker then 1/8inch, which is "closer" to what the frame is.

Here's some pics

[King7765]

Here's some pics of the metal pieces for the frame.

I used automotive primer to transfer the shape of the template to the metal for a more accurate result. I held the template down with four fingers near the edge and sprayed from high above straight down. I did this all the way around the template then let it dry which took maybe 5-10 mintues. It was far more accurate then a thick line left by a sharpie marker and reduced the grinding time when fitting it perfectly into the frame.

[dgfordman]

r u gonna leave the engine cross member there or get rid of it. im building a 96 ranger w/ hp 44,9inch, linked and coilovers. build looks good keep it coming.

[Fordman500]

what are you cutting with? I like where it going, did you rebuild that 60 aswell?

[King7765]

Here's the drivers side tacked and TIG welded. Also a pic of the front section of the passenger side. There is one more to go behind it.

Don't be ragging on the weld job, I bought a $100 Cebrora brand tig welder and was eager to use it. It goes to 100 amps, is a scratch start and has NO foot control. Very crude welder...

You'll see what I bought to replace that $100 tig welder later on in the posts.

[King7765]

The engine X-member is getting cut out. That next on the list as of right now (4-16-07).

I used a right angle grinder with a 5inch cut-off wheel.

[King7765]

Yes the Dana 60 got rebuilt. I have an ARB in the mail with 4.56's and a master install kit. The outter knuckles where completely rebuilt from bearings to the kingpins.

[King7765]

Here is the rear section of the passenger side...

[King7765]

Thats as far as I got with the frame so far.

I did however get some parts from summit. They make a cool little adapter that goes from the Ford EFI to an 8AN fitting. So I got this made....

Notice the guys from Nyco where able to remove the fitting that went on the gas tank and crimp the new braided line to it.

[King7765]

Oh, here's that EFI fitting....

[King7765]

I guess so far I've been waiting for PARTS!!!!!!!

Polyperformance was back ordered on their Currie Johnny Joints for like 3 weeks now. So when I get that order I'll have my frame brackets, my axle brackets, Johnny Joints, tube adapters, jam nuts, my nitrogen regulator to fill the 2.5 air shocks, 2 quarts of fox air shock oil, the little air shock syringe and probably some more stuff I forgot.

OK4wd is shipping my ARB, 4.56 gears, and install/rebuild kit.

Baja Concepts is shipping my 2.5 Air shocks which are also back ordered from FOX. (They were $50 per shock cheaper then Poly and shipping was only $20 from Cali to PA)

I have my 24ft of 2" x .250" DOM

All I need to do is order the High steer arms from Poison Spyder and TRE ends and some tubing for that stuff.

My 1.75inch die is coming in the mail from JD2 so my bender finally has a friend... That will allow me to make my shock hoops and my Transmission X-member. I have a cool idea for that by the way, because with as much drop as I'm hoping for, the driveshaft will hit the factory x-member.

AND best of all... I sold my Jeeo Cherakee for this...

[Fordman500]

damn thats a nice fawkin welder. i like where your going with it, it looks really good. cant wait to see some updates.

[King7765]

I've been wanting this welder for about a year!!!

I'm working on getting power to this welder. I got some 8-3 cable and I have some fancy 60amp 250V twist lock connectors coming in the mail. Once thats all hooked up I can fire that Miller up...

I don't know what I'll do this week. Depends on what parts come in first. Maybe I'll cut that engine X-member out, or at least post some pics of what my ideas are...

Time for bed, 2am is late when you got class in the morning...

[WHITE RHINO]

dang you now eberyone will think your cooler than me hahahahaahaa i was content with my miller 250 now i have to upgrade