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-   -   Project 'Rusalka' FX4 - Overland Beast (http://www.fordrangerforum.com/project-logs/142965-project-rusalka-fx4-overland-beast.html)

Jalapenio 10-20-2017 08:15 PM

Project 'Rusalka' FX4 - Overland Beast
 
Hola Ranger fanatics,
I was gonna do 4x4 swap on my Ranger, but good friend talked me out of it and instead I picked up 2002 Ranger FX4 with twin sticks. I'm completely loving it, and I think rear opening doors are best upgrade (including 4x4). It make's huge difference.
Going into this build I believe I have clear direction to take with it. It's gonna be overland rig, capable with some decent off road action. For early summer of 2018 I'm planning do some traveling along east cost and stick to live in truck itself.
Some info on truck:
2002 FX4, 5Speed with manual transfer case, 4.0 V6, 4.10 LSD in back, 238k on clock. Quite a bit but it had nearly no rust and frame is perfect, unusual for New England. Eventually gonna go with diesel swap (far future).

It needed some work so first two 3 months spent working on it.
- Intake gasket
- all fluids replaced
- air, fuel filter
- front suspension completely done (all by MOOG)
- completely cleaned and painted frame and anywhere underside that I could reach

Onto Pics:
Day I bought it, other Ranger next to it (May '17):

https://9miuzq.by3302.livefilestore....&cropmode=none
https://7yfpoa.by3302.livefilestore....&cropmode=none

Rebuild:

https://krljeg.by3302.livefilestore....&cropmode=none
https://pwqapg.by3302.livefilestore....&cropmode=none
https://yjsywa.by3302.livefilestore....&cropmode=none
https://wvttkg.by3302.livefilestore....&cropmode=none

Header panel was bit rough, some hammered all rotted pieces, cut rest out and welded metal patches to fix it.

https://vt9fia.by3302.livefilestore....&cropmode=none
https://jz08ca.by3302.livefilestore....&cropmode=none

Whole front end was ripped out and replaced with MOOG and Rancho shocks:

https://krlieg.by3302.livefilestore....&cropmode=none
https://wvtskg.by3302.livefilestore....&cropmode=none
https://jz07ca.by3302.livefilestore....&cropmode=none

While having front axle out, tried to put cover with drain on lower side but ordered wrong part. Apparently Dana 35 SLA is not same as Dana 35, So got my buddy combine both covers I had and fabricate drain in right one.

https://vt9eia.by3302.livefilestore....&cropmode=none

----------

Before truck got aligned cranked torsion bars 1.5 and started all the fun stuff. Put bigger alternator from explorer:

https://xsaktq.by3302.livefilestore....&cropmode=none

Started on restoring Rims, 3 hours per rim using strongest stuff I could get my hands on. Front needs more fine polishing but back is looking stunning. Before and After:

https://yjsxwa.by3302.livefilestore....&cropmode=none
https://pwqzpg.by3302.livefilestore....&cropmode=none

Dumped stock muffler and put cherry bomb with side exit before rear tire. Work in progress:

https://7yfooa.by3302.livefilestore....&cropmode=none

Also after having rear bumper for over year (originally meant for other truck) got brackets fabricated. It's Jeep bumper and it fit's perfectly.

https://xsavtq.by3302.livefilestore....&cropmode=none

By pure luck got front bumper from previous generation Ranger, kicked it farther to the front and mounted winch on it. For now it's only phase one still need to do few more things to it but it solidly mounted.

https://krlteg.by3302.livefilestore....&cropmode=none

Undrstm8ed 10-20-2017 08:34 PM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Subbed to see how this comes together...

Jalapenio 10-20-2017 08:48 PM

Re: Project 'Rusalka' FX4 - Overland Beast
 
And just to give you guys idea, that's how my Green Ranger looked like before it got stripped down to stock:

https://vt9pia.by3302.livefilestore....&cropmode=none
https://wvt3kg.by3302.livefilestore....&cropmode=none
https://yjs8wa.by3302.livefilestore....&cropmode=none

For now in pipeline for next month for Rusalka:
-over the cap ladder rack
- LED off road lights all around
- finish front bumper
- swing out spare tire holder
- wiring nightmare
- add a leaf with longer shackle

Jalapenio 10-30-2017 12:33 AM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Bumper all painted and winch wired in. Control box got hidden behind grill for cleaner looks.
https://9wqcpg.by3302.livefilestore....&cropmode=none
https://jrlleg.by3302.livefilestore....&cropmode=none

Undrstm8ed 10-30-2017 12:22 PM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Subbed

UltraHDGames 11-01-2017 06:03 AM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Subbed! Love overland builds!

Jalapenio 11-22-2017 09:28 PM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Nearly finished with fabricating ladder rack, started as short bed full size rack. Build proper brackets that sit in stake holes and shortened rack by few inches. Few small things left to weld and it can go for paint.

https://v1tsmg.by3302.livefilestore....&cropmode=none
https://xpsxya.by3302.livefilestore....&cropmode=none

99Ranger376 11-23-2017 12:19 AM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Subbed, looks great so far. Your old Ranger looked good too.


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Jalapenio 03-01-2018 02:12 AM

Re: Project 'Rusalka' FX4 - Overland Beast
 
It's about time I updated it a bit.
Ladder rack got fully finished and painted. Ended up adding mesh over cantilever, and LED lighting all around. Fabricating swing out for spare tire and Jerry cans.
On to half bad and good news, broke shackle mount and while fixing it discovered that leaf pack is completely shot. So new leaf pack, add-a-leaf and chevy drop shackles were installed.
https://iz1qua.by3302.livefilestore....&cropmode=none
https://vvqbcw.by3302.livefilestore....&cropmode=none
https://9wqu2g.by3302.livefilestore....&cropmode=none
https://xjtgoa.by3302.livefilestore....&cropmode=none
https://8miorq.by3302.livefilestore....&cropmode=none

12 Deg North Industries 03-01-2018 01:05 PM

Re: Project 'Rusalka' FX4 - Overland Beast
 
Nice work...

I am assuming you left the front of the overhead rack open for dual purpose (work) and that is why you didn't continue the expedition [like] rail around the front or back?


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