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Old 12-16-2019, 10:46 AM   #126 (permalink)
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Originally Posted by Dan90FSB View Post
Really enjoying this build, clean fab work. That t-case crossmember came out really good. Its like the quality of fab that I envision when I start most projects but then get impatient and/or run out of talent such that the end result often resembles something... lesser...
Thanks Dan. Your not alone, that's just how life goes sometimes. I decided the miter joints were questionable so added some band-aids (even the same shape)

Got the trans mount done on the mid cross member. Used the mill to make slots for the trans mount.


location came out like the predictions and given a 1/2" shim the mount put it almost flush with tube. It's currently 1/4" below old 2wd location as far as I can predict.


I added some little fishplates that resemble band-aids to strengthen the miter joints. Also put a 2nd crooked pass on the long sides. Not sure if this was needed but it's done now.


Re-installed and trans is now supported. The x-mem has to move forward to be removed from the frame. The trans mount has to come off to do so, but it works OK and will be serviceable enough.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s
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Old 12-16-2019, 11:53 AM   #127 (permalink)
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With cross members done I moved on to the front suspension. Placed the axle under the chassis and centered it at full compression height. Critical clearance were very close to math predictions, axle track bar is 1/2", Diff is 1". This yields 6" up travel and shock is 1" from bottoming out (shock is set up for 7 up 7 down, with a usable 6 up 6 down)


The left side is tight, but will clear the proposed track bar mount location with axle forward 1.5". Can't really move track bar mount forward, as steering box is already a tight fit, and can't move steering box because of radiator. So 1.5" it is, can't really get to 2". Track bar needs a slight bend to clear the diff cover at full compression, but looks like everything will fit.


In an attempt to pick a set of holes for track bar, I calculated bumpsteer ratio/offsets. The frame side track bar holes are offset horizontally quite a bit so kind of need to know to determine bar length. So I pressed in ball joints on the right knuckle to measure the drag link position. At full comp both the drag link and track bar are flat. Across travel the they are quite close at center/center position. Given the lengths are different there will be some bumpsteer but should be minimal and still have full adjustments.


Lowered axle to ride height to start on link bar fab. Bent a piece of conduit to get a general idea of angle and location of bend. After waffling for some time on details, I attempted to bend the 2" 0.25" wall DOM with my HF pipe kinker. The 12 ton ram deflected the baseplate of the bender but doesn't have enough to bend more than 2-3* So have to find a place with a bender or break out the wallet and buy one....
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Old 12-20-2019, 09:30 AM   #128 (permalink)
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Pulled the motor and drivetrain to finish the front half of the frame.



Added a little piece to tie the RA mounts to the x-mem mount


Re-calculated bumpsteer ratios. Have enough adjustment in track bar to get either direction of error. Committed to steering box location and drilled mounting holes. Added sleeves to prevent crush and keep bolts tight

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14 F-250 6.7 PSD, CCLB, 37s
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Old 12-23-2019, 10:18 AM   #129 (permalink)
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Thanks for sharing, love the build!
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Old 12-31-2019, 12:09 PM   #130 (permalink)
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Thanks man. Hoped to get more done over holidays but need one thing or another on motor, axle and suspension.

Got the link bars built. Made a temp track bar out of conduit to test fitment. Ended up moving bracket forward a bit, but still a tight fit. This is at full bump.


Track bar in but doesn't fit all that well. Didn't bend it enough to clear diff cover when left up and right not. May be able to bend this bar further, but it is good enough to get it down the road for now. This pic is at ride height.


I bent the lower bar 12* to allow for more tire clearance. I positioned the upper arm mount over the bend. The bend is not ideal and puts side loading on the bushing. Acceleration and braking will try to twist the arms. I think for my use it will be fine and the steering angle/turning radius improvement will be worth it.


at ride height


Need to finish weld the link bars. Probably have them TIG'd by someone better at it than me.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s
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Old 12-31-2019, 12:13 PM   #131 (permalink)
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I test fit the coilovers at full droop. Starting to look like it might actually make it down the road at some point.


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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s
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Old 12-31-2019, 12:22 PM   #132 (permalink)
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Working on the front axle while stuck on other items. Awhile ago after removing axles, I thought it would be a good idea to clean out the tubes with compressed air, but it just blew all the dirt into the diff.

So I figured I'd clean the diff. Removed the spider gears, but open diffs suck so having a hard time putting it back together. Not going to re-gear and buy diffs at this time, so thinking about just putting in a front lunchbox locker.

Any of the bunch better than the rest? The spartan is $100 cheaper.
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14 F-250 6.7 PSD, CCLB, 37s
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Old 01-03-2020, 12:50 PM   #133 (permalink)
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Originally Posted by rattle snake View Post
Working on the front axle while stuck on other items. Awhile ago after removing axles, I thought it would be a good idea to clean out the tubes with compressed air, but it just blew all the dirt into the diff.

So I figured I'd clean the diff. Removed the spider gears, but open diffs suck so having a hard time putting it back together. Not going to re-gear and buy diffs at this time, so thinking about just putting in a front lunchbox locker.

Any of the bunch better than the rest? The spartan is $100 cheaper.
I have done Lock rights, Spartans, and an Aussie. In my opinion they are all pretty much the same thing, so I would go with whatever is cheapest. The Spartan is slightly easier to install, but not enough for it to really be a factor in the purchase for me.

Supposedly the Powertrax No-Slip is supposed to behave more like a full-carrier auto locker (smoother and quieter), but I haven't used one since they are a bit more expensive because I have installed lunch box lockers in the past primarily because they were cheap.
https://www.powertrax.com/traction-s...nesize%3A_ANY_

From what I've read, the Torq locker is supposedly the strongest of the lunch box lockers, but it too costs a bit more, and I have no personal experience with it.
https://www.torqmasters.com/torq_loc...e_tl_16035_tor

Last edited by '84 Bronco II; 01-03-2020 at 12:51 PM.
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Old 01-06-2020, 01:02 PM   #134 (permalink)
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Looks like torq locker is the 'Ausie' locker. I ended up going with the Spartan.

Had a lock right in my 77 bronco for 8 years no issues. Ran just locked front on 33s for a long time. Re-geared, 37s, broke some stuff, then put a Detroit in the rear and cromo shafts all around.

Got the trans looking all sexy and ready to go in.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-07-2020 at 02:55 PM.
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Old 01-06-2020, 05:15 PM   #135 (permalink)
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Looks like torq locker is the 'Ausie' locker. I ended up going with the Spartan.
The Aussie and Torq lockers are both made by the same company (Torq Masters), but the Torq locker has machined interlocking "key ways" on the two case halves that mate to the cross pin as opposed to the Aussie which uses small pins to lock the case halves together like most every other lunch box locker. The Torq locker design has much more shear area.

Torq


Aussie


Regardless, I am sure you'll be happy with the Spartan. Good looking build.
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Old 01-07-2020, 08:42 AM   #136 (permalink)
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Ah, I see now, thanks for clarifying.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-07-2020 at 08:52 AM.
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Old 01-07-2020, 08:52 AM   #137 (permalink)
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Puttering on front acc. drive while waiting on other stuff. Cleaned up the original alternator bracket but it's big, ugly, up too high and has unnecessary provisions for other stuff, so I made a simple low mount bracket out of steel.

Going to run the old external regulated turd in an attempt not to add one more unknown to startup/break-in debacle. When I run out of other stuff to fart with, a 3G swap.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-07-2020 at 02:56 PM.
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Old 01-07-2020, 12:14 PM   #138 (permalink)
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your pics don't show
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Old 01-07-2020, 03:01 PM   #139 (permalink)
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re-linked. Still issues with IE, use Chrome instead. Evidently pirate/IE/google don't play well together.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-07-2020 at 03:02 PM.
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Old 01-07-2020, 04:30 PM   #140 (permalink)
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What kind of power steering pump do you have in mind for this truck? Saginaw?
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Old 01-08-2020, 09:36 AM   #141 (permalink)
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What kind of power steering pump do you have in mind for this truck? Saginaw?
Yes a Saginaw. Motor came out of a van so it came with a Saginaw pump and bracketry. The mount is way up and out so will make something to place it where I want. Need to get motor in the chassis to make location decision.
Had some luck in the past shimming pressure regulator for improved performance, so will reseal and shim the pump. Future plan is a redneck ram or equivalent.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-13-2020 at 12:55 PM.
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Old 01-08-2020, 12:34 PM   #142 (permalink)
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Spartan installed in the 60

Popped it back in and checked the patterns. still need a new spindle and a set of hubs, which are supposedly in process.
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Old 01-08-2020, 03:37 PM   #143 (permalink)
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Excellent work!
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Old 01-13-2020, 08:43 AM   #144 (permalink)
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winning
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Old 01-13-2020, 09:42 AM   #145 (permalink)
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Everything is looking good. This build is awesome, it's almost the exact same kind of build I want to do on my '78.
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Old 01-13-2020, 02:10 PM   #146 (permalink)
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Excellent work!
Thanks!
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winning
Cool, what game are we playing?
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Everything is looking good. This build is awesome, it's almost the exact same kind of build I want to do on my '78.
Thanks. Once the pieces start coming together there will be 'opportunities for improvement'.
Sounds like it's time for you to get going on that 78!

Farting around with the axle while waiting on parts. Supposedly have a D60 spindle on the way to replace the D50 one it had. Also picked up another D60 spindle from a buddy, it's beat up enough that he bought a new pair for his build. Sometimes a bigger hammer is not the answer. I was able to work the bearing surfaces (aka turd polish) enough to get bearings on it. The outer bearing surface is suspect but I'll run it if the other spindle doesn't pan out.
So If your going to wack your spindle, don't hit the bearing lands!

Ordered brake pads and a rebuild kit for the calipers thinking I had a '95 axle, but I don't it's the '94 and earlier type. So had to return and reorder brake parts. More delays, but that's how it goes.
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72 F-250 Explorer 2WD to 4WD conversion 460, C6, NP205, D60/S10.25, 40s
14 F-250 6.7 PSD, CCLB, 37s

Last edited by rattle snake; 01-21-2020 at 02:34 PM.
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Old 01-31-2020, 09:05 AM   #147 (permalink)
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Got the front axle mostly complete. Rebuilt calipers. All new everything.

power stop pads

money pit assembled.

Will see how G2 hub work out, was part of the pacakge deal.
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Old 01-31-2020, 07:34 PM   #148 (permalink)
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Looks mint, keep up the nice work.
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Old 01-31-2020, 08:04 PM   #149 (permalink)
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You take really nice photos.
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Old 02-02-2020, 05:34 PM   #150 (permalink)
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Looks great.

I've seen a few G2 hubs grenade on the trail but under pretty rough use.

I'm a big fan of the Yukons.

But then a hub as a weak link isn't necessarily a bad thing. Much rather break that than anything inward from there.
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90 Bronco with stuff
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