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mikey09120 03-19-2014 03:17 PM

2009 4x4 Ranger Build
 
http://i.imgur.com/xmjg3dul.jpg

Bought as a 2009 4x2 ranger.
Snagged a low miles front diff with 4:10 gears, a manual shift 1354 transfercase, got the 4x4 hubs/spindles installed.


Got a rear axle. It's a 31 spline 8.8" out of a 1990 econoline. Has: 68" wms, speed sensor to keep auto trans happy. drive flanges that are able to be redrilled to 5x4.5". and the driveshaft flange works with my current driveshaft. Decided against a 9" as it has none of the above. WIll be getting an e-locker and 4.10 gears to match the front diff.


Didn't take a picture after work but I removed the spring perches and shock mounts already.

http://i.imgur.com/9fAZhral.jpg

http://i.imgur.com/5wYOHjEl.jpg

Some updates. Big things coming soon!


New tool cart (Don't you dare ask what brand. All I will say is it was $107)
http://i.imgur.com/UKYHJsol.jpg

Surprise! 2.5x10 FOA coilovers
We will see what kind of quality this new batch of shocks has to offer
http://i.imgur.com/CzCOVODl.jpg

Also, my fiberglass panels came in this week!
http://i.imgur.com/tfRhYGLl.jpg

Got the stock shock towers off as well as the rest of the torsion bar bullshit. Cleaned up the frame
http://i.imgur.com/Bs5QKtZl.jpg

got the fiberglass mounted and some other doo-dads
http://i.imgur.com/lZJeyh4l.jpg

http://i.imgur.com/6fOLlVll.jpg

Just waiting for bushings to start my arms.


And the HF toolcart is well worth the money. Especially if you wait until theres a good coupon for it.

_________________________

Starting to extend my axles
http://i.imgur.com/YATGXWSl.jpg

_________________________
Extremely rough mock up arms yielded about 15" of good travel with axles in place.

Could push for more but don't want to stress the inner tripod joint. That is what is limiting my droop travel. Tires contacting fiberglass/inner fenders may prevent some bump travel but I will find out tomorrow when my 35" mtr kevlars come in.
http://i.imgur.com/jg8g7nhl.jpg

http://i.imgur.com/fX8qXBfl.jpg

_________________________

approximate width (pure guesstimation)
http://i.imgur.com/63z9oizl.jpg

Well there was a flash flood in town, so I did as all good men of our nature would do.
http://i.imgur.com/4RCgOqPl.jpg

Then shit got serious. This is full bump as of now (tire rubbing inner fender which will soon be trimmed down) The base of the arms are done; reinforcement coming soon.
http://i.imgur.com/eOUjGJ5l.jpg

This is full bump from the front.
http://i.imgur.com/GQDSauql.jpg

Here is a closer view at my arms, axles, and angles at full bump.
http://i.imgur.com/usbGjzdl.jpg

Little lower than desried ride height
http://i.imgur.com/MEPRzsQl.jpg

Trimming inner fender wells. Should end up with zero rubbing.
http://i.imgur.com/iFGCSAfl.jpg

And an actual photo of all the arms on and snugged down near ride height.
http://i.imgur.com/mjslXd1l.jpg

Dropped the front diff 1.5" to allow for more droop travel.
Inner fenders are all clearanced.
Started her up and drove her in and out of the shop.




Ready for the street races.
http://i.imgur.com/PtOqjbUl.jpg

Also, she rolls!
http://i.imgur.com/KbYrpx1l.jpg

Had to make new tabs off the frame. Lots of clearancing was done but now i have that otherwise wasted travel. Arms required some lower arm clearancing at full bump.

Anyways. Here's how the lowers were reinforced/ribbed. Should hold up fine.
http://i.imgur.com/2hAEYRLl.jpg

Had to clearnace the lower arms from the axleshafts at full bump since I
dropped the front diff.
http://i.imgur.com/WtPu261l.jpg

And heres the finished lower. Just need to patch up those now useless holes and mock up my shock tab placement.
http://i.imgur.com/R5Q6hn8l.jpg

BEGIN RANT


Well today was a gigantic shit show. Didn't realize dropping the diff would effect axle plunge as significantly as it did. At full droop, the tripod was all the way in the cup and at full bump the tripod was nearly pulled out of the cup. That obviously wasn't going to work so I returned the diff to its stock location.


But now my 2.5 x 10 coilover does not fit in between the axle and the tie rod at full lock. My solution is to make my shock tabs higher to locate the coilover spring cup above the axle allowing it to sit further back away from the tie rod. And since the ranger axles only allow 22* of driveline angle. I can only get about 13 inches of travel making much of my 10" stroke shock useless. Without the 4wd axles, I can cycle nearly 18" of travel. Kind of bummed about the numbers but there is not much more I can do with my budget.


Going to be picking up some 2.5 x 8 coilovers and running those as they are more practical and I will be saving the 2.5 x 10 for when (and if) I link the rear.


Alot has gone wrong and not according to plan (ie. taking longer than expected and running out of budget) but I'm hoping I can get this together by the 19th so I can drive her up to SLO.


Definitely learned some lessons and made some mistakes but that's half the fun.

Progress.


Got the sleeved axles all welded and done. Got the new 8" stroke coilovers mounted. Starting the engine crossmember to connect the two shock towers. Also installed limit straps.

http://i.imgur.com/BKj2mUfl.jpg

http://i.imgur.com/EeZ7ucfl.jpg

Gangster unnecessary grade 8 steering stops.
http://i.imgur.com/5y8lPyWl.jpg

And still need to sleeve the tie rods and add support tubes to shock towers. Also have to install ABS sensor, grease axles and install boots, finish welding arms and paint, and make lower control arm bracket crossmember.


Rear axle is now geared and locked. Now I have to install the new brake kit and weld the spring perches and shock mounts on.


Also need to mount bedsides and figure out a t-case shifter (more junkyard diving)

Some gangster shock tower bracing. Started the crossmember over the engine but didn't snap any pictures.
http://i.imgur.com/5szTPahl.jpg

http://i.imgur.com/rXt0007l.jpg

http://i.imgur.com/yaBRDzpl.jpg

http://i.imgur.com/NR8W3Jnl.jpg

And here's our compilation of halfway finished projects.


Our little trail Samurai, my dad's second race truck, Corvette, and an old Ford.
http://i.imgur.com/j2Xfugcl.jpg

Moved to SLO




And heres some updates I never posted. This is how she looked when i left to SLO.

some painting
http://i.imgur.com/8rwvEBsl.jpg

Well I'm up at school now. I'm a second year Mechanical Engineer at Cal Poly SLO. Not much updates since the last post. Drove it up and down the street some more and it feels good.
Still need to:
-front and rear bumpers
-mount fuel filler neck
-rear shock mounts
-mount bedsides
-tcase shifter
-lower control arm crossmember
-few other doo-dads

Truck is still in my hometown six hours away now that school started.
Not planning to link it right away. Most likely going to run stock leaves with some 2.0 oe replacements out back until I have more time/money.
Might be trying to get it towed up to my house so I can continue work here as any work done at home will be done by my father until I'm back for winter break.

When I do link it, I plan on having two traditional lowers. One parallel upper on the passenger side to keep the stock gas tank and bed and a panhard with a simple bedcage.

Some small updates:
http://i.imgur.com/XcyHHgAl.jpg

http://i.imgur.com/CadOvgcl.jpg

Tailights and bedsides mounted
http://i.imgur.com/koNL2MIl.jpg

http://i.imgur.com/5VyuQCCl.jpg

Guess what this is for
http://i.imgur.com/Sm5oy6Dl.jpg

http://i.imgur.com/l1aEyoIl.jpg

T-case shifter. This picture is with the case in 4lo (furthest back) and the seat all the way forward.
http://i.imgur.com/6tE257gl.jpg

http://i.imgur.com/C8e6Ihzl.jpg

Ride Height
http://i.imgur.com/vcBtSpJl.jpg

Seen here in the background is my brother, dad, and Sal, our employee and friend.
http://i.imgur.com/KmhshJYl.jpg

I think I'll cap these later on.
http://i.imgur.com/eC28QKUl.jpg

Shitty pic, but heres my front diff skid/lower control arm crossmember and you can also see my tcase skid back there. Both Steel
http://i.imgur.com/IqPtTc5l.jpg

http://i.imgur.com/wRBarUfl.jpg

http://i.imgur.com/nBmCeHIl.jpg

Went to Johnson Valley for new years...
http://i.imgur.com/oqXFHsYl.jpg

http://i.imgur.com/8hHYC8Kl.jpg

Some action shots
http://i.imgur.com/kwJ4H50l.jpg

http://i.imgur.com/t1U1TKYl.jpg

http://i.imgur.com/iyIB3dNl.jpg

First time "light painting"
http://i.imgur.com/7Fg516zl.jpg

Here is what I started with.
Tires hitting inner fender on driver side.
http://i.imgur.com/W1dtU1Yl.jpg

After some trimming and battery relocation.
http://i.imgur.com/E698Ndrl.jpg

And a short video of going full lock steering at full bump

http://s1025.photobucket.com/user/mi...04258.mp4.html

mikey09120 03-19-2014 03:26 PM

Re: 2009 4x4 Ranger Build
 
Some updates. So after freezing my ass off in Johnson Valley over New Years, I decided that seat heaters were completely necessary.

Running the wiring under the vinyl
http://i.imgur.com/K7rmPGnl.jpg

Switches in the cupholder. Heated seats are so nice… 3 settings. High and Lo and Off
http://i.imgur.com/CJqcXgQl.jpg

Switch panel marked off. Bottom is for my e-locker. Top is to disable ABS. Marked the centers of future switches.
http://i.imgur.com/O5IGo9bl.jpg

Shock Tower crossbrace.
http://i.imgur.com/dClAeb1l.jpg

Organized all my little trinkets (spare nuts/bolts/screws/fuses,etc) in case of emergency.
http://i.imgur.com/GSOSsJ0l.jpg

Lower Control Arm crossbrace/front diff skid (steel)
http://i.imgur.com/SBBbgWal.jpg

Here’s my t-case skid plate.
http://i.imgur.com/vRvdCuLl.jpg
http://i.imgur.com/bvlmNzBl.jpg


U-joints on the 4x4 rear driveshaft I bought went bad so I installed new ones, and then sanded and painted the driveshaft
http://i.imgur.com/Qs9fCg6l.jpg

Fire extinguisher mounted.
http://i.imgur.com/ObIZLbkl.jpg

Excuse the rushed job. Need to pull it back off and finish it but heres my whip mount.
http://i.imgur.com/ujyaGIMl.jpg

Rear bumper done! and led license plate bolts.
http://i.imgur.com/UvoMvgml.jpg

Spare in bed
http://i.imgur.com/rcWrgO1l.jpg

Look ma! No spare.
http://i.imgur.com/oEnCkk2l.jpg

How did I do that?!
http://i.imgur.com/JdZvysQl.jpg

I love overhead welding.
http://i.imgur.com/TrA6QFzl.jpg

This is my “spinner” 3/8 all thread with a super sick spare plastic thingy from casey4x4’s partystroke build.
http://i.imgur.com/kAckqOsl.jpg

LED dome light
http://i.imgur.com/ZpnsXmJl.jpg

LED engine bay light. Need to figure out a better way to run the wiring and get a mercury switch for it to automatically come on when the hood is up.
http://i.imgur.com/ea0vBbHl.jpg

Here’s how I trimmed my driver inner fender.
http://i.imgur.com/ndRDJDtl.jpg

And my passenger side didn’t need much. Some slight rub marks
http://i.imgur.com/WX2LBrXl.jpg

Went cruising in Pismo, does 100x better than my old ranger.
http://i.imgur.com/iafSLfHl.jpg

Then went exploring our local tv tower road and climbed this huge peak overlooking Morro bay, San Luis Obispo, Santa Margarita
http://i.imgur.com/HaL35aQl.jpg

Morro rock in the background. It was steep as shit.
http://i.imgur.com/sGh84gol.jpg

Went to Shaver Lake for some snow ‘froading.
Filling up
http://i.imgur.com/138sH80l.jpg

My friend Mile’s SAS Dakota behind me
http://i.imgur.com/vajTz3Yl.jpg

On the trail.
http://i.imgur.com/zK6TSMzl.jpg
http://i.imgur.com/4upPsx9l.jpg

Half way up.
http://i.imgur.com/BURkrlGl.jpg

I think they call this “rock crawling”
http://i.imgur.com/5dOTBNUl.jpg
http://i.imgur.com/CfoqZtsl.jpg
http://i.imgur.com/Pleao4El.jpg
http://i.imgur.com/xEoBHuDl.jpg

Some serious action.
http://i.imgur.com/Q66uxNAl.jpg

Stopped at the top for lunch.
http://i.imgur.com/y1bnI5wl.jpg
http://i.imgur.com/rEXOarQl.jpg

And a group pic
http://i.imgur.com/1Styx5Dl.jpg

Because ocotillo…
http://i.imgur.com/bo25onDl.jpg

My sleeved axles couldn’t harness the gnarness of me brapping over whoops in rally car mode (4hi). Yes I know dumb idea. So won’t be using rally car mode anymore. Good news is the axle failed at the sleeve material only, all my welds held. Plasma’d off the axle so I can drive her back up to San Luis Obispo .
So now I have this to work with… going with 1.5” .250 wall. This should hold up just fine.
http://i.imgur.com/pCIk57Kl.jpg

red sled ranger 03-19-2014 08:15 PM

Re: 2009 4x4 Ranger Build
 
Speechless. This truck is sex

Devon H. 03-20-2014 12:47 PM

Re: 2009 4x4 Ranger Build
 
really nice truck man. beauty

mikey09120 03-30-2014 06:30 PM

Re: 2009 4x4 Ranger Build
 
Been doing some work over my week long spring break.
This is how we buy tube. Thanks to my roommate’s Partystroke (build in progress).
http://i.imgur.com/mDEkvOAl.jpg

But first, some pics from the Ocotillo trip that blew my front axleshaft.
Trying to keep up with quads is not advisable in 4hi. Was a fun little trip though.
http://i.imgur.com/QOLIp5il.jpg

http://i.imgur.com/e0gV5MPl.jpg

Got to work on the new front axleshaft.
http://i.imgur.com/g3pu21ll.jpg

Here it is almost done. Doing 3 plug welds.
http://i.imgur.com/nKnHvCWl.jpg

All done! Working 4x4 again. Will be making another axle with this 1.5 .250 wall and swapping it in for my passenger side and keeping the .120wall axle as a spare.
http://i.imgur.com/YELM1eIl.jpg

Started prep for my front bumper. I redid the condenser mount to get maximum clearance.
Also capped the frame rails.
http://i.imgur.com/8ClZHXjl.jpg

http://i.imgur.com/SLzL16il.jpg

Also a snap shot of my ABS mounting bracket that had to be modified to allow my tires to clear at full bump.
http://i.imgur.com/TDJtkpwl.jpg

Installed a license plate surround and LED license plate bolts.
The bolts were $5 for the pair and one burnt out right when power was applied. Will be ordering some higher quality bolt lights that shine more white and less blue. Trying my best to keep the popo happy.
http://i.imgur.com/8bOfbXIl.jpg

And some random flex shots. Prerunner? Crawler? Why not both?
http://i.imgur.com/nb0ZsSCl.jpg

http://i.imgur.com/pdscFa8l.jpg

http://i.imgur.com/7AUoNIDl.jpg

http://i.imgur.com/pj7jYMGl.jpg

Also welded my axle tubes to my housing. Will be doing a simple truss on top soon.

Ordinary Biker 03-30-2014 06:44 PM

Re: 2009 4x4 Ranger Build
 
Nice. Some $$ and lot of sweat in that truck.

mikey09120 03-30-2014 06:57 PM

Re: 2009 4x4 Ranger Build
 
Here’s some pics from this past weekend in Ocotillo. First time going to superstition.
http://i.imgur.com/zp509yDl.jpg

http://i.imgur.com/og3NSvbl.jpg

Awesome views. And my magnetic koozie held on tight the whole ride!
http://i.imgur.com/UZoeZ5ml.jpg

The apple doesn’t fall far from the tree.
http://i.imgur.com/c7KxrQbl.jpg

Like father, like son. I hope one day to follow his footsteps into desert racing. Likely class 10, but I’m only dreaming.
http://i.imgur.com/AHEO22zl.jpg

Some more pics of my front axles.
http://i.imgur.com/HV1d57ql.jpg

http://i.imgur.com/SHbFImFl.jpg

mikey09120 04-18-2014 10:21 PM

Re: 2009 4x4 Ranger Build
 
Got some new toys.
http://i.imgur.com/pPOkGDal.jpg

http://i.imgur.com/OXEYN52l.jpg

Regarding the HF tube roller:
Quote:

Originally Posted by mikey09120 (Post 3557615)
Holy mother of god.
I bought the harbor frieght manual roller for $169 and it's a workout. About 3 passes in, the spot faces on the shaft pushed the set screw out so hard it pushed all the threads out. So with the help of my roomate (casey4X4) we cross drilled through the shaft and also the die and used a 1/4" socket head cap screw as a double sheer pin. Was doing some more rolling and it sheered off about 5 passes in. replaced with grade 8 1/4" bolt and its good to go. I'm on about 15 difficult passes and its still not my desired radius for the front bumper on my ranger. Definitely get the SWAG or whatever willis fab works has unless you want a good cardio session.


EDIT: 4/5/2014

Sheered 3 grade 8 bolts and still didn't get to my desire radius. Did 30+ passes with the the bender screw jack maxed out with a harbor freight earthquake impact (700ft lbs apparently). Gave up and put it in a regular mandrel bender. Will have pics soon. Looks unique with the rolled tube and the bends combined.

Getting nasty in the garage. Partystroke and Ranger under the knife.
http://i.imgur.com/v1srosSl.jpg

Got to work on the bumper.
http://i.imgur.com/FaIC2nPl.jpg

All finished up.
http://i.imgur.com/R8vb02ul.jpg

http://i.imgur.com/giFwjhal.jpg

http://i.imgur.com/aK8k2zsl.jpg

http://i.imgur.com/cweB79Tl.jpg

Then my truck became a parade float for our university’s Poly Goats 4x4 and Off-Road Club.
http://i.imgur.com/s8Zffwsl.jpg

After, did some more RTI rampage. This thing flexes way more than one would expect. A-arms for the win.
http://i.imgur.com/zr9NlS1l.jpg

Had some extra aluminum from the skid plates that I’ll use for my jack skid. I want to make it able to roll still.
http://i.imgur.com/TCxcJ3ml.jpg

Also, conjoured up this bad boy to fit in the method center cap. Opinions on looks?
http://i.imgur.com/NebNYIil.jpg

Front end.
http://i.imgur.com/ll6R8mpl.jpg

Full Droop.
http://i.imgur.com/BLSBkV5l.jpg

Fixed the wiring for the underhood light.
http://i.imgur.com/NcGjoull.jpg

Also, here’s my excessively bright dome light.
http://i.imgur.com/NeS72nkl.jpg

Engine bay.
http://i.imgur.com/WiUmRJPl.jpg

View from the roof.
http://i.imgur.com/1Rj8MWsl.jpg

http://i.imgur.com/7AbVqbbl.jpg

Bumper looks unique with the rolled tube and the bends. Can hardly tell the whole tube was rolled anymore though.
http://i.imgur.com/tMpSnQMl.jpg

cvar 04-19-2014 07:48 AM

Re: 2009 4x4 Ranger Build
 
Wow, you have talent! Beautiful job, and nice truck!

stephen 04-19-2014 07:56 AM

Re: 2009 4x4 Ranger Build
 
When you ditched your t bars did you make your own mounts for the shocks or did you buy them from somewhere? If you made them do you mind sharing your measurements and such? I really want to do that to mine.

WNH 04-19-2014 08:14 AM

Re: 2009 4x4 Ranger Build
 
https://www.youtube.com/watch?v=RLo4eZzdiDg
Hey man nice truck! First saw it in this video and wondered if you were on Frf

mikey09120 04-19-2014 09:41 AM

Re: 2009 4x4 Ranger Build
 
Quote:

Originally Posted by stephen (Post 2113091)
When you ditched your t bars did you make your own mounts for the shocks or did you buy them from somewhere? If you made them do you mind sharing your measurements and such? I really want to do that to mine.

Yes had to make my own shock hoops and shock tower cross brace (connects the two shock hoops/towers over the engine bay.

Measurements would be pretty irrelevant as every set up is different regarding shock angle, full compressed shock length, full extension shock length, lower shock tab placement, etc. There are alot of aspects that factor into making these shock hoops ideal for the setup.

Quote:

Originally Posted by WNH (Post 2113102)
https://www.youtube.com/watch?v=RLo4eZzdiDg
Hey man nice truck! First saw it in this video and wondered if you were on Frf

Yes, that was me and my club making a ridiculous big block go kart. I am mainly on dezertrangers but frequent hear at FRF as well to keep in touch with everyone.

stephen 04-19-2014 11:46 AM

Re: 2009 4x4 Ranger Build
 
alright i understand that. so as for the lower mounting points for the shocks you just have some bracket (home made?) welded on the reinforced lower arm correct? and after that just ditched the t-bars all together? you truck is bad ass by the way. its a shame your selling.

mikey09120 04-19-2014 11:15 PM

Re: 2009 4x4 Ranger Build
 
Quote:

Originally Posted by stephen (Post 2113302)
alright i understand that. so as for the lower mounting points for the shocks you just have some bracket (home made?) welded on the reinforced lower arm correct? and after that just ditched the t-bars all together? you truck is bad ass by the way. its a shame your selling.

Essentially yes. You have to make custom shock tabs on the lower arm and reinforce the arm with some internal ribs as the arms wasn't meant to take the stress of the coilover.

stephen 04-19-2014 11:24 PM

Re: 2009 4x4 Ranger Build
 
Quote:

Originally Posted by mikey09120 (Post 2114064)
Essentially yes. You have to make custom shock tabs on the lower arm and reinforce the arm with some internal ribs as the arms wasn't meant to take the stress of the coilover.

Awesome. Thanks man. I desperately need new shocks and I've been looking into doing this coversion when I get the old shocks out.


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