Found 131 matches

Re: Sparkydog's 2003 Safari AWD

Time to cut up the rear wheel wells. The stuff to make a cardboard template: 001.JPG Deciding on the shape of the curve and marking out on the template. 002.JPG Transferring the cut line onto both fenders. The right side will cut through more complex metal as it's tight in this area due to the slidi...
by Sparkydog
March 2nd 2021, 5:33pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: 2000 Astro AWD abs light at startup.

I believe the ABS light and brake light on together is the classic symptom of ABS module solder joints with cracks. And when temp changes the joint "heals". I did the DIY solder joint repair and it's been good ever since.
by Sparkydog
February 23rd 2021, 11:30pm
 
Forum: Brakes
Topic: 2000 Astro AWD abs light at startup.
Replies: 10
Views: 141

Re: Sparkydog's 2003 Safari AWD

A picture of my air intake housing support bracket. I'm not sure I'll keep it but for now it's good enough.
001.JPG

002.JPG
by Sparkydog
February 23rd 2021, 4:29pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Steve, awesome thread, thanks! When you were going to do the V8 swap, what all equipment did you use to lift the body? Thanks Cribbing Blocks under all 4 wheels to start with. 006.JPG Then higher up on these freakishly tall jack stands I made. 008.JPG All with the help from my favorite floor jack. ...
by Sparkydog
February 23rd 2021, 4:15pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

I finished plugging up the remaining holes on the air intake housing. 001.JPG 002.JPG 005.JPG 007.JPG And finished the installation of the temperature switch that will control the fan speeds. 017.JPG And started cutting up a practice body trim to see how "clean" I might be able to make the...
by Sparkydog
February 22nd 2021, 6:40pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Astro/Safari Faraday Shield...

Never in my wildest dreams did I think I would read the words "Faraday Shield" on this forum. :lol:
by Sparkydog
February 17th 2021, 9:17pm
 
Forum: Electrical
Topic: Astro/Safari Faraday Shield...
Replies: 9
Views: 165

Re: Sparkydog's 2003 Safari AWD

Oh yeah I forgot about this other mod to the exhaust pipe. I broke off 2 of the three studs on the muffler half of the connecting flange so I decided to just chop off the factory flange, weld a little bit of pipe back in and use one of these aftermarket couplings. The exhaust hangers were also exten...
by Sparkydog
February 15th 2021, 5:51pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Like many of you before me, I removed the 3 side molding pieces (that are easy to take off). Then I made my initial cuts into the rockers. These were not intended to change anything but just so I could verify what was inside the rockers before I made more serious cuts. 004.JPG 005.JPG After mounting...
by Sparkydog
February 15th 2021, 5:22pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

And last but not least, "It will turn!" I've done my preliminary fender clearancing - but first some glamour pics.
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036.JPG


And some details of the current shape of the fenders.
040.JPG

039.JPG
by Sparkydog
February 15th 2021, 5:16pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

With the e-fan mounted and the radiator being about 1.5" higher after my 3" lift but 1.5" motor mount lift, I needed to scallop the bottom of the air intake /filter housing a bit. A shot after I cut open the bottom of the housing and then added a layer of thick cardboard to create a s...
by Sparkydog
February 15th 2021, 4:40pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Here are some more pictures of my e-fan installation. The yellow things are my weird mounting brackets. I am proud of how they turned out. They had to dodge a lot of hoses and stuff and were a real challenge to mock up and create the threaded mounting points. 017.JPG 019.JPG Here's the humble origin...
by Sparkydog
February 15th 2021, 4:29pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Tree wins...

Back to the 4 wire vs 3 wire question - perhaps the 4th wire is for a heated mirror?
by Sparkydog
February 3rd 2021, 12:50am
 
Forum: Exterior
Topic: Tree wins...
Replies: 19
Views: 606

Re: Sparkydog's 2003 Safari AWD

dcsleeper wrote:> Did you preheat the work?


I have a MAPP gas torch so I used that to preheat - but also to keep it from cooling as best I could after the weld. Tack welds and shorter beads tended to crack at the end but a long bead and a bead that ended at solid metal did just fine.
by Sparkydog
January 20th 2021, 4:14pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Ford 8.8 Eaton eLocker build and install

Other potential Ford 8.8 donors with posi are Aerostars and Mustang V8's. Both of these axles do not have perches for leaf springs but since you need to relo the perches anyway... The Aerostar 8.8 axles were attached to a 3-link so the pumpkin has a weird "horn" off to one side. But easy t...
by Sparkydog
January 20th 2021, 12:28am
 
Forum: Rear-End
Topic: Ford 8.8 Eaton eLocker build and install
Replies: 31
Views: 1864

Re: Sparkydog's 2003 Safari AWD

As I went to reinstall the V6 exhaust manifolds I ran into what the internet says is a somewhat common thing The manifolds "shrink" enough that you can't get all the bolts back on. And the internet says I can buy a "stretcher" that looks like a heavy duty turnbuckle. I thought th...
by Sparkydog
January 19th 2021, 11:33pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

So back to my brain fart about where/what was causing the coolant leaks. When I replaced all the gaskets I put in new TTY head bolts. These bolts came "pre-loaded" with what I ASSumed was thread sealant. So I didn't add anything else to the threads and just proceeded with the proper TTY pr...
by Sparkydog
January 19th 2021, 11:22pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Before I forget here's how the sliding door does with the new tires and wheels. 002.JPG And I even remembered to swap the spare tires between the Burner and my van. The spare from the Burner is not the same brand or width as the meats on the wheels but it is the same diameter - about 31.5". Her...
by Sparkydog
January 19th 2021, 11:02pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Back before Labor Day weekend in the year of our Covid, my van started dripping coolant off the left side cylinder head around the middle cylinder. At the time I ASSumed it was either a head gasket or LIM leak. I eventually dropped the subframe about a foot so I could work easier on the motor and di...
by Sparkydog
January 19th 2021, 10:36pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Sparkydog's 2003 Safari AWD

Over the holiday weekend I wrapped up the 3" lift portion of my van. First I added a gusset plate to the forward spring perches. 009A.JPG And then I did the rear axle shock mount bracket mods. I had read the other threads about bending the stock bracket somehow but the pictures were links and t...
by Sparkydog
November 30th 2020, 10:24pm
 
Forum: Projects/Builds
Topic: Sparkydog's 2003 Safari AWD
Replies: 122
Views: 9060

Re: Rear axle "alignment" and rear tire wear

My brain interprets that sketch to mean that the rear end is jacked up in some manner and is causing the van to want to track to the right when its moving.
by Sparkydog
November 24th 2020, 11:12pm
 
Forum: Lifted Suspension
Topic: Rear axle "alignment" and rear tire wear
Replies: 94
Views: 2507
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