I figured I'd do a write up to show how easy it is to modify the inexpensive IRS Explorer/Mountaineer rear axle cover so that it can be used on most any solid axle 8.8" rear. That would allow it to be used in a Fox, S95, New Edge, or even an '05 GT and up or '07 and newer GT500. I have done this previously, to an '01 Explorer cover, and found it to be a rather simple mod.
What got me going again was a gentleman that posted shots of a similar cover on his GT500KR. I could tell right away that the cover looked like an Explorer unit that had been modified, much in the way I did mine. After tracking down the correct part, I was able to match that cover in about an hour using a couple of power tools. I used:
- Sawzall, with two different types of blades. I used a general rough in blade (~7" long) to make the majority of each cut. I then finished each cut with a Bi-Metal blade in a similar length.
- A generic hand held belt sander. I think the belt was 90 grit and it worked well for a quick clean up of most any cut.
- Beyond that, I only used a couple of large clamps to hold the cover down while I cut and sanded it.
The part number from Ford
Cover on left is the previously modified '01 cover. Cover on right is the '07 cover I just picked up
The nice thing about this cover is that it comes complete with bungs and magnetic plugs for both draining and a filling
In addition, there is a machined hole at the upper right hand corner (2 to 3 o'clock) for the vent that the Explorer uses. You could either plug this, use a vent, or use it as a return from a catch can, etc.
Another neat feature is that this cover uses a machined groove that works to capture rtv sealant inside it and stops gear lube from being able to leak. Being a deeper cover than stock, it also increases fluid capacity.
That said, I started the modification process by simply clamping the cover down to a plank on a couple of horses. I then made a quick outline of my intended cut line for the ear removal on each side.
The rough-in blade makes a quick slice through the aluminum
The other ear
I then laid out some quick reference marks to cut a taper to the now squared-off ribs
The pie shaped slices come off rather quickly
The other side
The cuts may look a bit rough on close examination, but not to worry. The belt sander cleans everything up just fine. Here's one side after only thirty seconds of sanding
Here are the cuts from the other side
Forty-five seconds of belt sanding later...
What it now looks like, sans ears, from the other side
That pretty much matches what was done to the cover that was installed on some GT500KR models. Since I'm a bit anal, I spent a few minutes cleaning of the casting parting line around the circumference of the gasket flange. I simply propped up the cover on its side and belted away...
To recap...
It turned out similar to my previous work on the older cover
Now get out there and start cutting!
Tob
On edit... note that Steve from Tousley has an even better price than what I paid. This ends up costing ~1/4 of the price of an aftermarket cover, and offers much more panhard bar clearance. It obviously doesn't have the load bolts that the FRPP unit does but I wanted the extra room due to my larger diameter Maximum Motorsports panhard bar and I'm not a fan of the relocation brackets that a few vendors sell.
What got me going again was a gentleman that posted shots of a similar cover on his GT500KR. I could tell right away that the cover looked like an Explorer unit that had been modified, much in the way I did mine. After tracking down the correct part, I was able to match that cover in about an hour using a couple of power tools. I used:
- Sawzall, with two different types of blades. I used a general rough in blade (~7" long) to make the majority of each cut. I then finished each cut with a Bi-Metal blade in a similar length.
- A generic hand held belt sander. I think the belt was 90 grit and it worked well for a quick clean up of most any cut.
- Beyond that, I only used a couple of large clamps to hold the cover down while I cut and sanded it.
The part number from Ford
Cover on left is the previously modified '01 cover. Cover on right is the '07 cover I just picked up
The nice thing about this cover is that it comes complete with bungs and magnetic plugs for both draining and a filling
In addition, there is a machined hole at the upper right hand corner (2 to 3 o'clock) for the vent that the Explorer uses. You could either plug this, use a vent, or use it as a return from a catch can, etc.
Another neat feature is that this cover uses a machined groove that works to capture rtv sealant inside it and stops gear lube from being able to leak. Being a deeper cover than stock, it also increases fluid capacity.
That said, I started the modification process by simply clamping the cover down to a plank on a couple of horses. I then made a quick outline of my intended cut line for the ear removal on each side.
The rough-in blade makes a quick slice through the aluminum
The other ear
I then laid out some quick reference marks to cut a taper to the now squared-off ribs
The pie shaped slices come off rather quickly
The other side
The cuts may look a bit rough on close examination, but not to worry. The belt sander cleans everything up just fine. Here's one side after only thirty seconds of sanding
Here are the cuts from the other side
Forty-five seconds of belt sanding later...
What it now looks like, sans ears, from the other side
That pretty much matches what was done to the cover that was installed on some GT500KR models. Since I'm a bit anal, I spent a few minutes cleaning of the casting parting line around the circumference of the gasket flange. I simply propped up the cover on its side and belted away...
To recap...
It turned out similar to my previous work on the older cover
Now get out there and start cutting!
Tob
On edit... note that Steve from Tousley has an even better price than what I paid. This ends up costing ~1/4 of the price of an aftermarket cover, and offers much more panhard bar clearance. It obviously doesn't have the load bolts that the FRPP unit does but I wanted the extra room due to my larger diameter Maximum Motorsports panhard bar and I'm not a fan of the relocation brackets that a few vendors sell.
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