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Old 03-19-2014, 03:17 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default 2009 4x4 Ranger Build



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.





Some updates. Big things coming soon!


New tool cart (Don't you dare ask what brand. All I will say is it was $107)


Surprise! 2.5x10 FOA coilovers
We will see what kind of quality this new batch of shocks has to offer


Also, my fiberglass panels came in this week!


Got the stock shock towers off as well as the rest of the torsion bar bullshit. Cleaned up the frame


got the fiberglass mounted and some other doo-dads




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


_________________________
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.




_________________________

approximate width (pure guesstimation)


Well there was a flash flood in town, so I did as all good men of our nature would do.


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.


This is full bump from the front.


Here is a closer view at my arms, axles, and angles at full bump.


Little lower than desried ride height


Trimming inner fender wells. Should end up with zero rubbing.


And an actual photo of all the arms on and snugged down near ride height.


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.


Also, she rolls!


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.


Had to clearnace the lower arms from the axleshafts at full bump since I
dropped the front diff.


And heres the finished lower. Just need to patch up those now useless holes and mock up my shock tab placement.


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.





Gangster unnecessary grade 8 steering stops.


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.








And here's our compilation of halfway finished projects.


Our little trail Samurai, my dad's second race truck, Corvette, and an old Ford.


Moved to SLO




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

some painting


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:




Tailights and bedsides mounted




Guess what this is for




T-case shifter. This picture is with the case in 4lo (furthest back) and the seat all the way forward.




Ride Height


Seen here in the background is my brother, dad, and Sal, our employee and friend.


I think I'll cap these later on.


Shitty pic, but heres my front diff skid/lower control arm crossmember and you can also see my tcase skid back there. Both Steel






Went to Johnson Valley for new years...




Some action shots






First time "light painting"


Here is what I started with.
Tires hitting inner fender on driver side.


After some trimming and battery relocation.


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

http://s1025.photobucket.com/user/mi...04258.mp4.html
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2009 4x4 Ranger Build


-Michael Danger Gonzalez
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  #2  
Old 03-19-2014, 03:26 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default 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


Switches in the cupholder. Heated seats are so nice… 3 settings. High and Lo and Off


Switch panel marked off. Bottom is for my e-locker. Top is to disable ABS. Marked the centers of future switches.


Shock Tower crossbrace.


Organized all my little trinkets (spare nuts/bolts/screws/fuses,etc) in case of emergency.


Lower Control Arm crossbrace/front diff skid (steel)


Here’s my t-case skid plate.




U-joints on the 4x4 rear driveshaft I bought went bad so I installed new ones, and then sanded and painted the driveshaft


Fire extinguisher mounted.


Excuse the rushed job. Need to pull it back off and finish it but heres my whip mount.


Rear bumper done! and led license plate bolts.


Spare in bed


Look ma! No spare.


How did I do that?!


I love overhead welding.


This is my “spinner” 3/8 all thread with a super sick spare plastic thingy from casey4x4’s partystroke build.


LED dome light


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.


Here’s how I trimmed my driver inner fender.


And my passenger side didn’t need much. Some slight rub marks


Went cruising in Pismo, does 100x better than my old ranger.


Then went exploring our local tv tower road and climbed this huge peak overlooking Morro bay, San Luis Obispo, Santa Margarita


Morro rock in the background. It was steep as shit.


Went to Shaver Lake for some snow ‘froading.
Filling up


My friend Mile’s SAS Dakota behind me


On the trail.



Half way up.


I think they call this “rock crawling”





Some serious action.


Stopped at the top for lunch.



And a group pic


Because ocotillo…


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.
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2009 4x4 Ranger Build


-Michael Danger Gonzalez
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  #3  
Old 03-19-2014, 08:15 PM
red sled ranger red sled ranger is offline
Ford Pickup
 
Join Date: Nov 2012
Posts: 109
Default Re: 2009 4x4 Ranger Build

Speechless. This truck is sex
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  #4  
Old 03-20-2014, 12:47 PM
Devon H. Devon H. is offline
Ford Tough
 
Join Date: Dec 2013
Posts: 429
Default Re: 2009 4x4 Ranger Build

really nice truck man. beauty
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32x11.5x15 Yokohama Geolander AT/S on 15x10 MT Classic Locks.
Superchips, Flow Master 4" tip. Kenwood DDX 470 head unit, Kicker Comp S 10" sub, Kicker 600.1 amp. Pre Keys cranked, shackles, K&N intake, reversed Ranger emblems.
Build Thread: http://www.fordrangerforum.com/proje...ml#post2062485
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  #5  
Old 03-30-2014, 06:30 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default 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).


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.




Got to work on the new front axleshaft.


Here it is almost done. Doing 3 plug welds.


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.


Started prep for my front bumper. I redid the condenser mount to get maximum clearance.
Also capped the frame rails.




Also a snap shot of my ABS mounting bracket that had to be modified to allow my tires to clear at full bump.


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.


And some random flex shots. Prerunner? Crawler? Why not both?








Also welded my axle tubes to my housing. Will be doing a simple truss on top soon.
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2009 4x4 Ranger Build


-Michael Danger Gonzalez
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  #6  
Old 03-30-2014, 06:44 PM
Ordinary Biker Ordinary Biker is offline
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Default Re: 2009 4x4 Ranger Build

Nice. Some $$ and lot of sweat in that truck.
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  #7  
Old 03-30-2014, 06:57 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default Re: 2009 4x4 Ranger Build

Here’s some pics from this past weekend in Ocotillo. First time going to superstition.




Awesome views. And my magnetic koozie held on tight the whole ride!


The apple doesn’t fall far from the tree.


Like father, like son. I hope one day to follow his footsteps into desert racing. Likely class 10, but I’m only dreaming.


Some more pics of my front axles.


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-Michael Danger Gonzalez
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  #8  
Old 04-18-2014, 10:21 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default Re: 2009 4x4 Ranger Build

Got some new toys.




Regarding the HF tube roller:
Quote:
Originally Posted by mikey09120 View Post
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.


Got to work on the bumper.


All finished up.








Then my truck became a parade float for our university’s Poly Goats 4x4 and Off-Road Club.


After, did some more RTI rampage. This thing flexes way more than one would expect. A-arms for the win.


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.


Also, conjoured up this bad boy to fit in the method center cap. Opinions on looks?


Front end.


Full Droop.


Fixed the wiring for the underhood light.


Also, here’s my excessively bright dome light.


Engine bay.


View from the roof.




Bumper looks unique with the rolled tube and the bends. Can hardly tell the whole tube was rolled anymore though.
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2009 4x4 Ranger Build


-Michael Danger Gonzalez
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  #9  
Old 04-19-2014, 07:48 AM
cvar cvar is offline
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Default Re: 2009 4x4 Ranger Build

Wow, you have talent! Beautiful job, and nice truck!
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  #10  
Old 04-19-2014, 07:56 AM
stephen stephen is offline
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Default 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.
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Old 04-19-2014, 08:14 AM
WNH WNH is offline
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Default 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
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  #12  
Old 04-19-2014, 09:41 AM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
Join Date: Apr 2010
Posts: 255
Default Re: 2009 4x4 Ranger Build

Quote:
Originally Posted by stephen View Post
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 View Post
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.
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2009 4x4 Ranger Build


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Last edited by mikey09120; 04-19-2014 at 09:44 AM.
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  #13  
Old 04-19-2014, 11:46 AM
stephen stephen is offline
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Default 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.
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Old 04-19-2014, 11:15 PM
mikey09120 mikey09120 is offline
Michael Danger Gonzalez
 
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Default Re: 2009 4x4 Ranger Build

Quote:
Originally Posted by stephen View Post
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.
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Old 04-19-2014, 11:24 PM
stephen stephen is offline
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Default Re: 2009 4x4 Ranger Build

Quote:
Originally Posted by mikey09120 View Post
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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