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  #31  
Old 07-28-2015, 09:04 PM
afkrejci90 afkrejci90 is offline
Ford Tough
 
Join Date: Oct 2012
Posts: 386
Default Re: afkrejci90's 02 XLT build

Finished wiring up the LED light bar and took it out for a test run on the backroads. Not bad for a $200 amazon bar.

This shot is with the headlights on.
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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #32  
Old 01-26-2019, 07:13 PM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

Haven't been on here for quite a while lately. So here's a little update on what has gone on so far. The rear doors have succumb to the usual rot found in these trucks. These were beyond salvageable so I picked up some new used doors to refinish.



A few pin holes poking through the skin but nothing some fiberglass filler can't take care of, at least the seam was still intact.









All filled up and ready for some primer



Shot the lower portion of the inside cavity of the door with some internal frame coating to seal up any exposed metal inside, which is probably why these rust out to begin with. Finished it of with a coating of fluid film to keep any moisture from making its way to the metal.





First coat of primer to find any imperfections or low spots.



Final coat of primer before color and clear



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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #33  
Old 01-26-2019, 07:30 PM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

All painted









Added seam sealer to the seam gaps to prevent any moisture intrusion or a place for it to sit and rot the door again from the inside out. Didn't come out looking like a factory applied job since the sealer I used was really a quick skinning sealer, most of it will be hard to see anyways.





Only got a shot of this one side. The color is a bit off since the surrounding paint is badly faded, plus red is a hard color to match anyways. The whole truck will probably be getting repainted soon anyways so the slight difference isn't much of a problem right now. At last I have doors that latch completely and can now have interior lights.



Since my doors latch now and the truck doesn't 'see' open doors, I can finally run interior lights now so I decided to swap them out to brighter LEDs. Found a killer deal on headlamp bulbs for the plow so I switched those out too.









On a side note, picked up a new daily driver so I can devote more project time to the ranger. Up next is replacing the rotted out bed and working on rust proofing the the frame and fixing any remaining body rust.

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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #34  
Old 01-26-2019, 08:14 PM
IA Transplant IA Transplant is offline
Spray Painted Ranger
 
Join Date: Jan 2019
Posts: 114
Default Re: afkrejci90's 02 XLT build

looks real nice, I just found out the rubber coating right under the window peeled off after I tried taking some ice off of it...
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2001 Ranger XLT 2wd | 18" TSW Sonomas
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  #35  
Old 02-29-2020, 02:07 PM
afkrejci90 afkrejci90 is offline
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Default Re: afkrejci90's 02 XLT build

Been awhile since I have updated this thread, here's the progress I've made so far. The plan was to repair the floor of the bed but it was just beyond repairable as the front mounts were not even attached to the bed anymore.



Decided to get a donor bed and just bought an entire truck since finding a bed in decent shape by itself would be challenging. It's also a 4.0 4x4 so I was thinking of pulling the engine and doing a rebuild to put in mine.



Took the bed off and cleaned up most of the rust and removed those heat shields that were causing the rust.



If you ever wondered why all the wheel well arches rust here it is. I ended up replacing both sides just to take care of any hidden rot.



Cleaned up the top of the wheel wells and sealed it off with some POR-15.





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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #36  
Old 03-05-2020, 08:10 PM
afkrejci90 afkrejci90 is offline
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Default Re: afkrejci90's 02 XLT build

Got the panels welded back in after tackling the rust. Reused the panel on this side as there was only some light surface rust.



Applied some fiberglass body filler over the welded areas







Got some new fender flares to throw on.

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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #37  
Old 03-07-2020, 08:02 PM
afkrejci90 afkrejci90 is offline
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Default Re: afkrejci90's 02 XLT build

I picked up a spare cluster a few years ago and just never did this upgrade. Most of the bulbs in my cluster finally went out so why not do some custom work? Hard to drive this at night with only two backlight bulbs working.



Laid down some LED strips to even out the light spread instead of just using 194 bulbs. I did use LED replacements for the 194's since there are light pipes for each socket.



Used a buck converter to ensure the strips don't receive a voltage higher than 12v since the alternator charges at about 15v, not easy to replace if they burn out.



Sanded off the green tint and went with a color scheme similar to the new F series trucks. It looks way better in person, the green tint makes it look dated.

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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #38  
Old 03-09-2020, 09:39 AM
afkrejci90 afkrejci90 is offline
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Default Re: afkrejci90's 02 XLT build

The cab corners are shot and of course there are no replacement panels for this cab style so I'll have to make my own.



Went to town with a hammer looking for all the soft spots.





It broke through into the body mount cavity



Cleaned up the rust as best as I could and hit everything with a few coats of a rust converter.



Beginning the process of rebuilding the corner by scratch.

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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #39  
Old 03-12-2020, 07:08 PM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

Extending the rocker panel all the way to the back of the corner. No more cavity with a piece of plastic plugging up the hole.



Completing the rest of the lip on the rocker.



Couldn't use the edge from the replacement panel so I had to make a new piece for that.



Before closing in this corner I hit every seam possible with seam sealer to prevent any intrusion of moisture.



Tried to use as much of the original material as possible but after throwing it in the blast cabinet I wasn't left with much. Made this curve so I would have something solid to shape and weld the sheet metal to.



Fitting the last large piece.



Getting everything tacked together and lined up in its original position.



Wasn't sure how to make the curved pieces to fill the gap near the pinch welds, so I threw in some backing metal to hold the body filler.



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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD

Last edited by afkrejci90; 03-12-2020 at 07:26 PM.
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  #40  
Old 03-13-2020, 05:30 AM
ford4thot ford4thot is offline
2019 SSVT Ford 'Maro
 
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Posts: 14,636
Default Re: afkrejci90's 02 XLT build

Noice
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  #41  
Old 03-26-2020, 06:27 PM
afkrejci90 afkrejci90 is offline
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Default Re: afkrejci90's 02 XLT build

The other side is in worse shape, I'm surprised the step bars didn't rip off with any weight on them.







This ended up being too rotten to try and replace and I didn't feel like wasting time trying to build all of this back in. The body mount is still solid so I just converted the rust and cocooned it in place.



I didn't get a clear picture of but you can sort of see how I sealed up the rotten area.





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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #42  
Old 03-28-2020, 08:00 PM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

Using most of the original metal as I can, bead blasted and cut back to good metal.













Finally got the hang of spot welding, long tedious work.



Finished welding and now ready to move on to the filler work.

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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #43  
Old 03-28-2020, 08:28 PM
afkrejci90 afkrejci90 is offline
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Join Date: Oct 2012
Posts: 386
Default Re: afkrejci90's 02 XLT build

Started off with applying fiberglass filler and get the rough shaping down and matching the door gap.

















Etch primer for any exposed metal.



Filler primer to make any flaws visible and rework the panels if needed.





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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #44  
Old 03-29-2020, 08:34 AM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

A coat of epoxy primer for maximum corrosion resistance and seam sealer to keep the salt out.









I hate spraying red but this time I got the color to match much better.





Not bad for a 2k rattle can. Used spraymax clear since I didn't want the garage being coated with clear coat dust.







Doors back on and rolled out of the garage. There are holes still in the rocker panel, didn't have time to tackle that I was trying to get the corners done to get back out and start pushing snow again. I'll take of that in the coming months.



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'02 Ranger 4.0 SOHC XLT
3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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  #45  
Old 03-30-2020, 02:31 PM
afkrejci90 afkrejci90 is offline
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Posts: 386
Default Re: afkrejci90's 02 XLT build

Alternator was not up to the task, didn't realize I only had a 95 amp. Bearing in this thing were shot and the voltage regulator was draining my battery. Upgraded to a 370 amp JS alternator, also did the big 3 upgrade.



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3" PA Body Lift, 2" T-Bar Crank, Duratrac 285/75/16
'17 Civic 1.5T 6SPD
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