My Build Thread - Clifford

[kbldawg]

Got me to thinkin, you should buy that explorer motor in the shop and really get this project movin! where else can you buy a motor and have the same guy help you install it would want to buy some different heads though??

Ben

I was going back through the build thread and saw this.

Saturday we were putting that explorer motor in, exactly a year later. Spooky!

 

[jpopsbronco]

Ok, so for those of you running 35's and no power drum brakes, you know why this was high on my list of things to get done. Eating the back-end of someone's Lexus was at the front of my mind everytime I took her out for a cruise.

Hahaha before i got hydroboost id go out for a spin and come back with wet pants and red paint on my bumper, now i just come back with a bloody forehead and a smashed up front window haha good ole hydroboost

 

[kbldawg]

Got some more done today...

Clutch Rod to extend - DONE
hook up/adjust clutch - DONE
drive shafts to bolt back up - DONE
radiator hoses to hook up - DONE
battery tray and battery install - DONE
engine wiring - DONE
swap steel dizzy gear over - Destroyed Distributor trying to get gear on
spark plug cables and boots to install - No Dizzy
bend gear shifter - DONE
install t-case shifter - DONE
install electric fuel pump - DONE
install oil filter adapter - arrived today - WRONG PART - Reorder - DONE
bolt check, fluids - DONE
exhaust - DONE
crank engine - DONE
set timing, idle...etc. - DONE
test drive - DONE
rebuild the carb. - DONE

 

[bigmuddy]

Dammit we were so close !

Ben

 

[kbldawg]

Dammit we were so close !

Ben

Yeah, we were doing good and then the whole distributor gear issue pretty much "shut her down".

Oh well, it will make the "crank engine" step that much more exciting. ;D

 

[broncosport]

One word!!! ILOVEIT!!! What I would do to have the time and money to accomplish what you have!!!

 

[kbldawg]

Thanks, bud.

What isn't so obvious is the length between each phase of progress. There were several months of nothing between the last bit of work and now.

The engine swap was conceived a year ago, and parts gathering started late Decemeber.

Extra jobs pay for most of it and my wife bought me the tranny. I'm getting the engine by bartering for some construction projects. So, the biggest portion of the money I've spent has been on all the smaller parts and peices. That's the stuff that will eat your budget.

BTW, when I was at Malmstrom, AFB in MT. They had an automotive center where you could go rent a bay (with 2 posts lifts, paint booths, metal work rooms...etc) and tools...etc. Do they have that at the base your at? Someone should do that for the civilian world. It was a big hit at Malmstrom.



good luck on your build.

 

[broncosport]

Yeah they have one at Whiteman AFB but I have most of the stuff in My garage, that I need! My build will get a nice jump start again when My new garage is completed! I'm working in a space thats about 12X22 and the new garage will be 24X30 with a 12 foot overhang for My DD! should be a good upgrade!!

 

[kbldawg]

Sometimes it's the simplest things that hold up a major project.

I've been trying to find the correct part so that I can screw my oil filter on the engine block for about 3 weeks now. Yeah, I know. %) The exploder motor uses a factory oil cooler setup that my motor didn't have. Unlike most 5.0 blocks, the filter adapter on the exploder is all ass-backwards and so I needed the right adapter.

I went to summit first, and they sent me a "sandwich adapter", which had no chance of working. I checked two different ford dealerships and neither of them knew what I was talking about and didn't seem to care. Finally, somebody on Bronco Fix told me to search for "5.0 Oil Filter Adapter" on e-bay. I don't usually have good luck with ebay, but lo and behold some guy has a truck load of them for $5/peice.

I got it in the mail today and finally...I have everything I need to get that motor cranked and tuned up.

Keep yer fingers crossed on that!!

 

[BroncoJAK]

Well it's about stinking time! ;D

 

[kbldawg]

Yes it is, John! You'll be happy to know that I got a new exhaust system today too! ;D

I'll get some better pics later on...

All trailered up and read to go...

Thanks BroncoJAK for the use of the trailer, she's a butte!!!!

One of the muffler guys that just didn't ever seem to get in a hurry.

These guys did a great job and kept everything high and tight. I went with 2.25" to the y-pipe, then a single 2.5" the rest of the way out. The sound is nice and mellow and the best part...NO MORE LEAKS!!!!!!

It's missing pretty bad and sluggish right now, but you can tell that the power is in there, I just got to get it out.

 

[kbldawg]

Exhaust

Here's some pics of the exhaust...

 

[kbldawg]

Well, we got her done!! For the most part. lol

I've still got some loose ends to tie up before she's ready for the road, but it's drivable again.

I thought I'd update with some pics...

New 5.0 Explorer Engine w/ GT40P heads...

The plug wire socks and upgraded wires are to prevent over heating due to how close the stock eb exhaust manifolds are to the spark plugs. It's a really tight fit, but I think they will work out well with this setup...

The passenger side isn't near as tight as the driver's side.

Passenger Side close-up

Driver's Side close-up

Getting the shifter bent for the NP435 was quite the ordeal, but we got it. I ended up cutting 3 inches off the top of the shifter to clear the dash in first gear. The added benefit of cutting the shifter is much shorter throws on 2nd, 3rd, and 4th gears.

and here's a look at reverse (the other extreme)...

and neutral...

bent as close to the driver as possible with a slight tweak at the end too...

I need to do some finish work and paint, but...very happy with the way it turned out.

Thanks again for everybodies input and help on this project. Especially bigmuddy for all the time and effort and the use of your shop and tools you are the man!!!! From my recolection, I owe you two gear pullers, a pin punch, and whole truck load of beer!!!

I'm gonna work on tweaking and fine tuning it all and try and enjoy all the hard work and $$$ before I start on the next project.

 

[phred]

Looks good. Nice job on the shifter.

 

[bigmuddy]

I was glad to help Chad. I had a ball working on the flying tomato

I wish I had someone around threw the years to lend a hand with all the broncos I have worked on. Now get that carb rebuilt!

Ben

 

[kbldawg]

More work...

I bought this carb from a member here and they suggested it be rebuilt. Even though it seemed fine, I thought it was good idea.

Well, I tore the carb down and got it rebuilt. Actually, I did it twice. %)

The first kit I got was for the 2100 and it was missing some parts and the gasket was wrong.

I went ahead and used it because I was trying to get ready for a trail run. Long story short, I decided to get the right kit and go through it again.

So, with the correct kit in hand I tore her down...

This kit had a new needle, that wouldn't work with my float. The needle was too long. So, I used the shorter needle from the 2100 kit (still new parts). It was also missing something else, don't remember what it was at the moment.

Using both kits I was able to get all new parts and I got a good rebuild this time.

So, I wouldn't recommend the GP Sorrensen Kit that's sold at Advance Auto and AutoZone.


I also had to take the driver's side exhaust manifold off and do some more carving on it. My spark plug wires were getting too hot and melting the boots.

I also sealed up a leaking transfer case bolt, ran my front and rear axle vent lines and changed the oil.

Tomorrow, I'm going to start her up and get her all tuned...provided nothing else goes wrong.

 

[kbldawg]

Tune Up

Well, it took me a while, but I finally got this thing tuned up. I had tried several different adjustments but there was always something bugging me.

at 10BTDC, Idle 800rpms I had a little pinging and dieseling.

so, I tried adjusting the idle down to 750rpm that didn't help, I tried going a little higher, no help, so I knew it had to be in the timing.

I set it at 12BTDC and readjusted the idle back down to 750 - 800rpms and no more dieseling. ;D

I suspected some bad gas as the cause of the pinging so I put $20 worth of 93 octane and immediately the pinging was gone. After I run that through it, I'll try some more 87octane and see if it's still there.

I went for a little joy ride and got some poser shots...

I've got to rebuild the rear drive shaft, fix the ARB leak in the 9", and figure out where my coolant leak is coming from.

Chad

 

[JWMcCrary]

Congrats Chad, I know you been working at it for a while, nice to see you driving it. Rig looks great.

 

[kbldawg]

I found some JC seats at the local U-Pull It. They are out of a Mazda 626. $40 bucks and some frabrication.

These seats are real nice and firm, enough bolstering to keep my rear in place and easy to slide in and out of. They have a real nice look to them and the color was perfect for my color scheme.

The driver's side seat bottom tilts, and both recline and have quality sliders. The mounting brackets for the rear were cut off and shortened. The fronts were fine. I wasn't able to reuse any existing seat holes because these sliders are a lot wider than the stock sliders.

If you are much taller than 6', these seats wouldn't work out to well for you. They sit a little high. I could take another inch out of the front brackets but that's about it.

Crappy cell phone pics...

Before:

After:

 

[FRANKO289]

Looks Good ... Nice Work !!