http://forums.hybridz.org/topic/117668- ... -for-s30s/
(look at the link is got more details)
Alright I'll come clean. I have been working on what I will call the best IRS swap for S30s. I have been running my setup for ~9 months now without a single issue. This eliminates every weak link that I know of, gives plenty of differential/gear options, uses minimal custom parts, and will hold a LOT of power. So on to the details, starting from the inside going out towards the wheel:
8.8 IRS differential from 02-05 Explorer/Mountaineer. Woooo! Gear and differential options! 8.8 parts are plentiful and cheap.
Custom stub shaft I produce that allows a porsche 930 CV Joint to bolt on. Driveshaft Shop also sells the same shaft at ~250 a piece. 31 Spline.
Porsche 930 CV Joint
Porsche 930 Axle. Chromoly off the shelf axles run 220 a pair!
97-03ish F150 Front CV axle OUTER CV Joint. Heres the secret, this CV joint uses the same splines as the porsche 930 axle. It splines into the hub with a 33 spline shaft. This thing is beefy. Definitely no stub shaft failures happening here. Parts stores stock the axles.
2000ish Dodge Intrepid Front Hub. Here is the even bigger secret. This hub uses the same 33 splines as the F150 front CV axle. Has a 5x4.5 bolt pattern(Easily redrilled to 4x4.5 for those looking to stay with stock 4 lug). Parts stores stock these for cheap
Custom Strut tower that the Intrepid hub bolts to
Wilwood 4 piston calipers, 2 piece rotors. More budget friendly brake setup is in the works, but this is the current setup
Now let me go ahead and address the "Man this guy is crazy, that is the most frankenstein setup ever." thought that is in your head. I won't lie, reading of the list sounds frankenstein. Dodge Hubs, F150 outer CV, explorer diff, (My setup uses Honda S2000 rear brakes and makes it worse), etc etc. Yes there are a lot of different parts going on, but they are stocked at parts stores, they are cheap, and they are strong.
The only driveline part that is breakable is the 31 spline to 930 CV adapter. I take the stock stub axle and weld on a flange that the 930 CV bolts to. I don't foresee these being an issue, but if they are, the DSS ones are an option, they are just expensive. If the porsche 930 stuff becomes a weak link, they sell 300M CV Joints and axle bars that will definitely not be the weak link. Every other part that is in harms way is an off the shelf part, 930 stuff is very common in the buggy world.
Kits will be available soon(Hope its ok to say that here). I will post in the vendor section with prices hopefully within a couple weeks. The custom parts include:
Front Differential Mount.
Rear Differential Mount. Billet aluminum, similar to what AZC sells.
Upright/Dogbone piece(One piece unit connecting the 2 dropdowns to the rear LCA mount). Needed to clear differential mounting points
8.8 to 930 CV Adapter(Requires sourcing explorer rear CV Axles and sending me the stubs, or I can source them for you)
Custom strut tower with bolt on strut tube. Similar to the TTT setup they sell for the R230 swap.
Small axle spacer(Splines on F150 axle are longer than the Intrepid Hubs)
The wilwood rotor hat needs the inside bore turned slightly larger to fit the intrepid hub. Currently working on a better solution for this, but its an easy fix.
Driveshaft(Not provided by me)
Those are the only custom parts you need. All the coil over parts are off the shelf, off the shelf brakes, off the shelf axle parts, etc. You would need to source an IRS differential from an explorer and the rear cv axles from the same vehicle.
I will try to get some pictures posted later, sitting in class right now. Texis300 will be recieving the first set hopefully within a week(Sorry its taking so long bud). He will be making close to 700 wheel I believe and will be putting this setup through some stress for sure. I only make a wee little 350rwhp, so I'm not a good test of this setups capabilities. I don't see Texis300 breaking anything, but thats not say he wont. I will make modification to the setup if he finds a weak link
Also, for those thinking they don't need the extra strength of the 8.8 differential. This setup will work the same way with the R200 and a bolt on 930 adapter. That will make the kit cheaper(No differential mounts). It will eliminate every weak link from the axles out, making the new weak link the differential or the differential stub shaft. I know SunnyZ was breaking the Z31 axle stubs, but maybe the stock R200 pieces are stronger? I can't remember if I've ever seen anyone break the stock differential stub shaft. Going with this setup will make the kit very affordable(Not that it isn't with the 8.8, but less custom parts makes it cheaper obviously)
Now I will open the floor to questions, comments, etc. Hope I didn't bore anyone with the book I just wrote
-Will
