Long Travel Prerrunner project.

[RaceRanger97]

Finally, After months of gathering parts I am tearing my DD apart and putting a whole new long travel set-up.

Before:
http://i220.photobucket.com/albums/dd33/RaceRanger97/DSC00996-1.jpg

some of the parts::
http://i220.photobucket.com/albums/dd33/RaceRanger97/new004.jpg

First I striped out all the old suspension and set in the new 5 inch wider beams::

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild004.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild008.jpg


Set in the engine cage::

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild010.jpg


http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild013.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild016.jpg


Alot wider:

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild011.jpg

He was pretty excited about the new radius arms:

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild020.jpg

Then we set in the new Tranny X-member:


http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild021.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild023.jpg


Not too bad for the first night I think.

[AgPete139]

Awesome! Looks nice. Do you have a wider, side-shot of your truck with the new setup?

[colinrmitchell]

That's a really sweet setup. Where do you go about getting parts like that?

I've never had a project go bad with a big jug of Mountain Dew on hand!

[compleckz]

good work, nice parts

[koda6966]

Awesome! Looks nice. Do you have a wider, side-shot of your truck with the new setup?

I don't think its done yet.. the first picture which is what I think your talking about is the "before" picture. I think.

[blue88b2]

I like prerunners!!! Nice rig!

[JohnnyU]

Set in the engine cage::


http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravelbuild016.jpg


Get rid of those junk carriage bolts, they're worthless. Get some grade 8 fine thread fasteners, use a washer on both sides and either a nylock or mechanical locking nut.

I think there should be an additional gusset in the center of that plate to wrap around the tube as well, but it may be fine without.

[RaceRanger97]

Get rid of those junk carriage bolts, they're worthless. Get some grade 8 fine thread fasteners, use a washer on both sides and either a nylock or mechanical locking nut.

I think there should be an additional gusset in the center of that plate to wrap around the tube as well, but it may be fine without.

HAHA don't worry those were just what I had laying around to see where everything lined up...and I have a bunch of extra metal to truss it once its in the right spot.

[RaceRanger97]

Awesome! Looks nice. Do you have a wider, side-shot of your truck with the new setup?

Thanks! ya like Koda said its not nearly done et but ill have a front wide shot as soon as its done.

[RaceRanger97]

That's a really sweet setup. Where do you go about getting parts like that?

I've never had a project go bad with a big jug of Mountain Dew on hand!

Thanks. Nearly all of these parts were bought off Race-Dezert.com .. And ya, you can never have too much Mountain Dew haha

[c_note]

did you get that set-up from a guy in SD named ricco? ha!

[RaceRanger97]

did you get that set-up from a guy in SD named ricco? ha!

If your talking about the cage then ya kinda...I bought it off the guy that ricco sold it to...same ricco that had the j-beam long travel set-up along with the cage?

[philzilla]

Those are race runners right? cool to see someone on here do an actual longtravel project, most of them are just lifts

[ZMan]

i love it

[koda6966]

Your floor jack looks kind of beefy. Whats the weight limit on it?

[RaceRanger97]

I first saw your ranger on youtube awhile back when you were doing some good jumps. Now that you are doing the entire setup that makes it much better. The I-beam rangers are the best in the business for off roading and they can take one hell of a beating. How much wheel travel do you expect to get out this? Are you gonna eventually do a 4-link in the rear or something similar in the future? I have always love the look of the 93-97 standard cab ranger prerunners, only when they are done right. Not that home made crap. I see a few are in Diego, I know when I used to live there that's all there was. Once in a great while you might come across one that has actually been built professional, others were a bunch of shit. How is the 2.3 with all the beat downs that you do to it while your out in the fun zone?

Ya I stoped posting vids on youtube a while back..ive tweaked with the suspension a bit since then and got some pretty good air..With this new set-up im hoping for about 18" of wheel travel. The 2.3 does great, it scoots just fine on the dunes with the 4.56's..I redline it all day with 148k miles and it has no complaints....yet

[RaceRanger97]

Those are race runners right? cool to see someone on here do an actual longtravel project, most of them are just lifts

Ya they are 2.5x14 race runners

[RaceRanger97]

Your floor jack looks kind of beefy. Whats the weight limit on it?

3 ton

[RaceRanger97]

I didn't get too much done today because it was the 4th of july but we welded in the shock hoops, finished the breaks, most of the stearing, and set in the first coilover. pulled rediculous amounts of down travel.

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel009.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel007.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel008.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel010.jpg


My Miller 250 was down so we welded with a 50 year old stick welder. Came out suprisingly well.


http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel012.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel013.jpg


http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel011.jpg

[RaceRanger97]

This is a good looking ranger along with the lift that you are putting on to it. Looking forward to see the results of this one. Are going to change the color of the shock hoops?

ya im painting everything black....ill have pics up tonight i just drove it down the street.

[94STXRanger]

Where did you get the radius arms and tranny xmember from, they look beefy.

[RaceRanger97]

Where did you get the radius arms and tranny xmember from, they look beefy.

I bought them off a guy on race-dezert he made them himself i believe.

[c_note]

the tranny x-member looks very similar to the camburg x-member.

[c_note]

[QUOTE=RaceRanger97;168301]

http://i220.photobucket.com/albums/dd33/RaceRanger97/longtravel010.jpg

QUOTE]

i believe that aluminum ring above the red anodized is supposed to be a stopper for the slider. i may be wrong tho since im not using one for my set-up.

[organic]

Wow, very cool! Thats gotta be real fun to play with. Man, I wish the underside of my 95' was in that good of shape, damn rust.

[RaceRanger97]

the tranny x-member looks very similar to the camburg x-member.

Ya thats what the guy based it off of

[RaceRanger97]

The srings are way too stiff and I have to bend the beams a little more to get rid of some camber issues.

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS001.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS005.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS006.jpg



FLEXED OUT:

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS007.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS004.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/TRS008.jpg


ill post more pics after i get it alligned and get the beams bent on monday

[koda6966]

Holy crap that's alot of camber!

[RaceRanger97]

Holy crap that's alot of camber!

HAHA ya....it really didnt sit like that..the toe was set way too far out so when i backed up it pushed the suspension togather and lifted the truck alot. When i drove forward the front droped like 5 inches.

[94STXRanger]

Camber issues? Looks fine to me!

[RaceRanger97]

I mest with the springs a bit and got it to sit pretty good..it will get me to the alignment shop tomorrow.


http://i220.photobucket.com/albums/dd33/RaceRanger97/done001.jpg

[koda6966]

Are prerunners street legal or do you have to trailer it?

[AgPete139]

Update on the alignment? If not, you may want to pull your toe-in a couple more rotations and it may make the drive to the shop a lil more comfortable.

It looks good man. What ended up being you total front wheel travel?

[JohnnyU]

What rate coils are those? I think that's your real problem....

[RaceRanger97]

Are prerunners street legal or do you have to trailer it?

most of them are street legal...when thet get real crazy with 4 link rear and fuel cells they become illegal

[RaceRanger97]

Update on the alignment? If not, you may want to pull your toe-in a couple more rotations and it may make the drive to the shop a lil more comfortable.

It looks good man. What ended up being you total front wheel travel?

thanks..ya i gotta mess with the toe a bit b4 i drive too far. im having the beams bent a little more so it should be sitting flat by tonight. the total travel was just over 20 but i will limit it at 18

[RaceRanger97]

What rate coils are those? I think that's your real problem....

350 over 450

[Dishtowel]

most of them are street legal...when thet get real crazy with 4 link rear and fuel cells they become illegal

huh, how come? Jeeps have factory 4 linked rear axles and they are legal.. (right?) Why would a fuel cell modify legal-ness? (nobody tell Evan, lol.)

[RaceRanger97]

huh, how come? Jeeps have factory 4 linked rear axles and they are legal.. (right?) Why would a fuel cell modify legal-ness? (nobody tell Evan, lol.)

I was talking in california..where 90% of them are..fuel cells and that extreme of a modified suspension isn't legal.

[dusto2]

ya it is legal just not the fuel cell thing also tires need to be under the fenders and stick out no more than 1 inch i think

[Boggin]

awesome ranger!

another thing, if ya want to do multiple quotes in one post (rather than pulling a "boggin"..--[kind of cool that there is a term named after me btw..]--),
rather than quote several times causing 3 or 4 posts you can click the button next to "quote" that has the quotation marks and the little plus sign, click it and it will turn red, click it on every post that you want to quote, and than the last one you can just press "quote" and there you go :icon_thumby:

[c_note]

how much did you preload the springs?

[RaceRanger97]

how much did you preload the springs?

i backed it off to zero for now...

[ZMan]

are those stock ibeams that have been cut and lengthened?

[RaceRanger97]

are those stock ibeams that have been cut and lengthened?

Ya..when i get everything set the way I want i think im gunna tig weld plating across both sides of the beams.

[fastford04]

this looks sweet!

[KELLY88]

That is one hell of a nice looking truck. I don't know hardly anything about prerunner suspensions so this is cool to follow.

[RaceRanger97]

That is one hell of a nice looking truck. I don't know hardly anything about prerunner suspensions so this is cool to follow.

Thanks ..ya its alot different from everything else..I was into 4x4 trail trucks for years till I rode in a prerunner on the dunes..now im hooked on the faster side to off-roading lol

[RaceRanger97]

Did some painting and added limit straps today..

http://i220.photobucket.com/albums/dd33/RaceRanger97/moretrs005.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/moretrs002.jpg

[KELLY88]

Looks good. I love the zip-tied shock reservoir.

[RaceRanger97]

Looks good. I love the zip-tied shock reservoir.

haha ya..temporary. got some actual resi mounts on the way

[JohnnyU]

That steering worries me. If it were me, I'd use a piece of DOM tube and either thread the ID to accept a TRE or use a tube adapter of the same thread. The way it is cut off and welded in place with the stock adjuster just doesn't sit right with me.




I'm not trying to be negative, I'm just pointing out the few safety/reliability/durability things I see that I have an issue with.

[RaceRanger97]

Shes finally all done..taking her to the dunes this weekend..well see how it does.


http://i220.photobucket.com/albums/dd33/RaceRanger97/random480.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random481.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random482.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random485.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random483.jpg

[Cwheeler]

thats a sick truck man, a prerunner was my first choice for a build but alas not meny dunes up here LOL lottas moutains so ive got a trail truck. thats a serious truck non the less get some action pics:beer:

[84projectFORD]

the truck looks AWESOME! i just started to build a prerunner myself but its an 84 so im doin the motor, trans and rearend swap first, then suspension. Couple things on your truck though. i would add a gusset under that little flap of metal that sticks out on your radius arm where the limit stap tab is welded too. the more you hit full droop the more that strap pulls on that lip and it will bend and also why so much spring? these trucks usually run a 250 350 spring set up. you may notice it to be just a little stiff in the sand but in the dez it will be way stiff for that truck in teh whoops and fast sections of rough road. not bashing or anything just want to see you not have probs and curiousity.

[RaceRanger97]

How did the long travel kit at the desert this past weekend? That ranger turned out really good I am impressed with it. It reminds the 92 that I had 7 yrs ago that my friend were building things were fine until the dimbshit destroyed it.

thanks alot..That sucks about the truck..how did he destroy it? The truck didn't make it last weakend :(.. i need to get a drop pitman arm before i can drive it on the street...i was gunna trailor it with my dads V10 Ford but with these gas prices and 6 miles per gallon i just didn't have the funds..so im hoping to take it out there mid next week on my day off.

[RaceRanger97]

the truck looks AWESOME! i just started to build a prerunner myself but its an 84 so im doin the motor, trans and rearend swap first, then suspension. Couple things on your truck though. i would add a gusset under that little flap of metal that sticks out on your radius arm where the limit stap tab is welded too. the more you hit full droop the more that strap pulls on that lip and it will bend and also why so much spring? these trucks usually run a 250 350 spring set up. you may notice it to be just a little stiff in the sand but in the dez it will be way stiff for that truck in teh whoops and fast sections of rough road. not bashing or anything just want to see you not have probs and curiousity.

Thanks..ya i do have extra plating so i think i will add to the radius arms thats a good idea.. well i used that spring weight because its gunna be a couple of months before i get some hydraulic bumps and i dont want to be bottoming out every where...plus they are only charged to 100 psi right now so it doesn't seem to get stiff till near full bump which is pretty much what i need for now..good luck on your build btw..

[philzilla]

cool to see this build up, ive always wanted to make an Ibeam ranger but currently saving for a dirtbike, lets see some pics of your trip

[KWAD RCR]

Got to see this truck in person today and it looks WAY COOL!!!!!! Hey Alec be sure and post more pics when you put on the 6 inch flare fenders you're gettin from me. OH yeah...I decided that I'm gettin the bad end of the deal if we trade straight across so..........I get your fenders AND ride in your truck for my fenders. :icon_thumby:

[RaceRanger97]

Got to see this truck in person today and it looks WAY COOL!!!!!! Hey Alec be sure and post more pics when you put on the 6 inch flare fenders you're gettin from me. OH yeah...I decided that I'm gettin the bad end of the deal if we trade straight across so..........I get your fenders AND ride in your truck for my fenders. :icon_thumby:

Haha yeah for sure! cant wait to see how they look on the truck..as soon as i get the steering figured out we'll go for a mob sesh! :headbang:

[RaceRanger97]

Thanks to Kwad RCR I got 6" flared feenders! looks alot better and i dont have to worry about the tires hitting.


http://i220.photobucket.com/albums/dd33/RaceRanger97/newfenders003.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/newfenders002.jpg

[RaceRanger97]

did a few things recently


moved the battery to the back for better weight distribution.

http://i220.photobucket.com/albums/dd33/RaceRanger97/random488.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random489.jpg

http://i220.photobucket.com/albums/dd33/RaceRanger97/random490.jpg


Ive been working on a rear bed cage to run some 14" shocks and new springs..ill have pics up soon.


http://i220.photobucket.com/albums/dd33/RaceRanger97/random526.jpg

[canyoncritter]

are those drop brackets I see?

and if you need a pitman arm still I have one, its a little beat up, but works fine.pm me if your interested.

[RaceRanger97]

are those drop brackets I see?

and if you need a pitman arm still I have one, its a little beat up, but works fine.pm me if your interested.

if you mean the beam drop brackets then ya...they are temperary till i finnish my other beams...it has a 4ich drop pitman arm on it now..thanks though

[marcehboy]

Hate to ask this but how much do you have into it?

[RaceRanger97]

Hate to ask this but how much do you have into it?

honestly im not even sure any more...probably like 5,000 in the main parts and tube work

[marcehboy]

Thats pretty good

[Mutant Pony]

The truck looks good! I sure would like to get a set of those shocks, A little much for me though.
One thing, I learned almost 30 years ago. Never, never weld vertically on a frame. You can get away with a stitch no more than 1/3 of the frame height. That includes seperate stitches in line. You will be extremly lucky if your frame doesn't break at the welds of the shock hoops! In the pic you didn't weld the bottom horizontal which would have been the most important weld if any at all. Welding horizontal on a frame will only make it stronger. Full length vertical is an absolute no-no!!!
The battery box is perfect! it looks like something I would do! I would put a cover on it though. One day on the dunes will have it filled with sand to the top and it looks like it would be pretty hard to empty.
I'm not trying to be a jerk, That is how I see it. I would be proud to own that truck.

[Dr.Unk]

In All My Life I Have Never Heard About Not Welding Horizontally On A Frame. Not To Be A Dick But I Dont Buy It.

[Dr.Unk]

My Mistake Vertically

[Mutant Pony]

Try it. Just don't drive it on a Highway!
When you weld steel it changes the temper of the steel next to the weld. I don't know the technical terms because I don't use them enough to remember them. What happens is that the frame breaks right next to the weld. There is ways to avoid this but, it requires putting the work into a furnace while you weld it then slowly cool it.

[Dr.Unk]

I Have Built Countless Amounts Cages & Shock Hoops Plated And Fully Welded To The Frame On Trucks That Get Punished Regularly. Never Had A Problem With Cracking.

[Mutant Pony]

Welding the tube directly to the frame would be fine. A circle is not a straight vertical line. I've personally seen frame failures from vertical welds.
Another thing that works is to turn the plate so that it is two diagonal lines.

[marcehboy]

wow ive never heard anything like that either i dont see how it could be true. Not doubting you just would like to see the scientific reasoning behind it

[AKBroncoII]

It tempers the steel at the heat affected zone causing it to become brittle. Being that the frame sees a lot of vertical stress, this causes problems. IMO, welding straight vertically is a big no no.

[RaceRanger97]

Well I looked though this thread and I have some good safe advise for you. For starters. The beams need more plating, the radius arms should have a gusset in between the tubes (especially if they are made from mild steel),the shock hoops need more bracing (coilovers require and engine cage with triangulation), and the coils should always have 1-2" max pre-load (if not you need to change the spring rate or check to see if they are mounted correctly) You have a good base and from what I can see its all fixable. As far as welding on a ranger frame goes. it doesn't mater how you weld on it. Its a C-channel frame and will crack regardless of what its made of. C-channel frames flex period! The only way to eliminate the problem is to box it in or/and cage the truck front to back with the proper design. Frame flex is what can cause the frame to crack. In this case the tube will eventually crack before the frame does. Adding some triangulation and more kicker tubes will allow it to last longer though.

thanks for the advise...i already have allot of that fixed. I have added alot more metal to the engine cage, I have a new set of coils with plenty of preload, and i am in the process of a new set of beams. once i finish the new beams (i am actually trying to save a bit for set of used threat beams i found on DR lol) I will most likey make new radius arms that are heimed..I build this truck w/o ever really seing another prerunner in person before, living so far north. Now that i know ALOT more and helping friends doing similar builds, doing alot of trial and error, the truck should take a turn for the better really soon.

[marcehboy]

thanks for the advise...i already have allot of that fixed. I have added alot more metal to the engine cage, I have a new set of coils with plenty of preload, and i am in the process of a new set of beams. once i finish the new beams (i am actually trying to save a bit for set of used threat beams i found on DR lol) I will most likey make new radius arms that are heimed..I build this truck w/o ever really seing another prerunner in person before, living so far north. Now that i know ALOT more and helping friends doing similar builds, doing alot of trial and error, the truck should take a turn for the better really soon.

I know what you mean I wanna build a prerunner to hammer on out in the northeastern terrain but every single prerunner ever made is on the other side of the country. Ill build mine without ever seeing one in person. Most of the people out here think im crazy for even thinking of building a 2wd off roading truck!!

[ckblum]

Same boat as you two, except Im in British Columbia. People think ultimate off road vehicles have to be 4wd with 44 boggers and stacked block lifts lol. They think their lifted Toyotas and monster solid axle trucks could waste in the Baja 1000.

[marcehboy]

yep here its the same thing...basically if its 2wd it junk

[ckblum]

Haha I need a sticker like that now. Sucks man I can't buy any used parts off of RDC or dramarangers.com (formerly dezertrangers.com), no one wants to ship to Canada, but the parts are soooo cheap and I totally can't afford new stuff because I'm a broke college student. I guess Ill have to just learn to fab my own stuff, Im taking an aerospace structures program so maybe I can stay after class and do some "extra-curricular work".

How much to extended beams typically weigh? A kid said his were 75lb each but it also has spindles and rotors on it.

[marcehboy]

Yeah that sound good Boggins for babies

[84projectFORD]

Haha I need a sticker like that now. Sucks man I can't buy any used parts off of RDC or dramarangers.com (formerly dezertrangers.com), no one wants to ship to Canada, but the parts are soooo cheap and I totally can't afford new stuff because I'm a broke college student. I guess Ill have to just learn to fab my own stuff, Im taking an aerospace structures program so maybe I can stay after class and do some "extra-curricular work".

How much to extended beams typically weigh? A kid said his were 75lb each but it also has spindles and rotors on it.

you ought to really start talkin to dave about some kits. i have been talkin with him back and forth over what i want for my race truck and for prices, all i got to say is WOW. lets put it this way, the prices you see on RDC and dramarangers for other kits used is pretty close to daves stuff NEW! plus he makes kits kinda geared toward what you will mostly be doin with your truck so you dont pay more for something you dont really need. I know im soundin like a damn sales rep or somethin but i willb e buyin my equal lengh beams, radius arm, brackets, dana 44 spindles and everything from him when the time comes :D:icon_hornsup:

[ckblum]

Yea I talked to Dave and he gave me a quote on a kit that would basically include everything to set my truck up real nice. I would like to shell out the money, just gotta wait until I have a room paid for on campus and I gotta buy some tools still. I will most likely have some money to put aside, Ill just have to see how much cause there is still a few things I would need on my truck like a locker and maybe even another set of tires.

[84projectFORD]

ah i got ya. man i knda sucks your so far away cause id love to help you out but im all the way at the bottom of the US in Arizona lol. let me know if there is anything i could maybe help you out with

[marcehboy]

Im in the same position, I'd love to buy a kit from dave just dont have the money yet.

[84projectFORD]

yeah i hear ya. its funny though, if youlook real carfully or call and get the details on one of those kits from RDC or dramarangers 90% of the time you dont get the radius arms or no hardware or no spindles or brackets so in the long run you pay more. But some times you get lucky and find one for a great price and inclues evrything!

[ckblum]

Yea man. It's all cool, I'll see what I got after my tools and maybe a few paychecks I can get a locker and at least some leveling springs and bilsteins to bomb around with for now. I found some decent tires for a good price too, just waiting on a reply.

[marcehboy]

Yeah ive got it made since my dad is a mechanic and has so much tolls he doesnt have a place to put them in one of his 5 boxes. Dont know what im going to do when i move out :icon_confused: hahah

[rangerboy92]

hey love the truck and to those who live in areas . like south carolina in my case , youll be amazed what a 2wd locked tuck and a pair can do

[RaceRanger97]

Thanks, I have a much more updated thread tittled Raceranger's Build you may care to check out.