After scoring the Currie housing, torque arm mount, axles, explorer brakes, and center section from the classifieds here, I'm making some progress finally. Couple problems too, so I figured I'd document everything here. Here's what I started with:



So the center/pinion support needed to be blasted to remove the surface rust on them:






Then primed and painted:



Then I removed the small amount of crap from the carrier bearing race bores with a wire wheel, then coated them and the adjusters with oil. Everything mic'd perfectly @ 3.25":

 

Then I realized the brakes weren't complete. They were missing the flex hose kit, 1/4" spacers, and a single wheel stud. So I ordered the parts from currie. Problem was that the spacer needs to go between the wheel bearing and axle retaining plate. It takes up the void created by the explorer brakes backing plate, and prevents the axle/wheel bearing from moving outward.

So in order to install then I had to remove and reinstall the wheel bearings, or so I thought. Currie informed me that the bearings would have to be replaced if removed because of the one time use design of the inner races.

@ $70+ dollars each no thanks! So I cut the spacers to fit around the axle, then welded and ground them to clear any interference. Since the spacers are only that (a spacer) this will work perfectly well and save me from having to replace the axle bearings:





Then I picked up the full rear axle brake lines from pick n pull (no pics). I'll have to modify the lines of course, but no big deal.

The parking brake cables will be another mini project. I pulled 95-01 explorer passenger side cables thinking that I'd mount the calipers in front of the axle and have the cables exiting the rear the same way LS rears do. However after deciding to put the caliper behind the axle, the cable will now exit toward the front of the vehicle. After some measuring, I believe the 91/92 disc cables will work perfectly. More on that when I get to it.

The I found out that the torque arm mount would not bolt up to the housing. After using a 5/8" end mill and removing a VERY small amount of metal from the torque arm, everything fits fine:




Because the housing sat for a while before I purchased it, the inside of the axle tubes needed to be cleaned. It took some innovating, but it came out well. Before:

after:

 

Then I welded on my Spohn LCA relocation brackets. Followed by primer/paint:





And this is where the rear sits now:


Still to go in:

Detroit Locker 31 spline, coated:

 

4.57 gears:



Also purchased a Strange install kit, Motocraft XG-14 gear marking compound, Summit dial indicator, Matco inch pound torque wrench (no pics)

Will update shortly......