My 99 Ranger Build Thread


RJLougee

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I've been wanting to build a Ranger for a while, my daughter finally killed hers, so I have a new project... I've been building old Broncos for many years, so will adapt some EB parts into the build.

How it looked when I started:



The tear down has begun...



I started tearing it down June 1st and have made some progress. Kind of a mock-up of how I want it to look when I'm done:





What do I want it to do when I'm done: I love Moab, so Pritchet Canyon followed by Behind the rocks and then drive back to camp. I have a full on buggy for when I want to do 90 across the desert, I want something a little more street-able... And by that I mean mostly legal to drive on the road.

Final specs will be:

Engine is a 351W, MAF EFI with the FRPP harness and an A9P EEC.

Trans is an AODE-W/4R70W with a Quick-4 controller.

Transfer case is a 4 speed Atlas.

37" or 40" tires, 40s are in the mock-up pic.

Custom frame. I have some 2X3" rectube on the mock-up, but it might be easier to just build it out of 1.75" round tube.

Rear axle will be a full-float 35 spline 9" with a True Hi-9 center section, 4.86 gears.

Front axle will be a hybrid 44/60, 35 spline inner/outer, 4.88 gears.

Major questions I haven't answered in my head are interior or exo cage? Or a hybrid of the two? I like an exo to keep the body off the rocks some. Other side of the coin, I'm probably not mounting seats/harnesses to the floor...

Final wheelbase, I'm thinking @120" to keep the break-over angle reasonable.

And a question: Does anyone make a decent set of flares for the front end that will allow me to move the front axle forward @6" and still cover? I'm looking at trimming the fender off so it cuts through the corner right below the bottom corner of the signal lens.

All thoughts appreciated.
Joe
 
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RJLougee

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I'll be using EB frame horn motor mounts on the rectube. Got a section of old EB frame and cut the mounts off, gotta love a plasma cutter:




And how the look cleaned up:




And then spent hours cutting and grinding to get the old stubs pressed out of the inner C knuckles for the hybrid axle:



Darn tedious that... But, this way I can have a buddy lathe out the inside of the tube so it's a good press-fit over the D44 tubes and press/weld it all back together.

The Quick 4 got here...



That's all for now.
Joe
 
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troyhecker99

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Gonna be an awesome build. Hope everything goes well and can't wait to see the progress.
Also I think I hybrid cage would look really good and I would also recommend going with the 40's.
 

RJLougee

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Progress Pics

More progress over the last few days.

Got the Engine/Trans/Transfer mocked up and measured out:




Saturday morning I took the inner knuckles in and my buddy Don opened up the inner diameter of the D60 tube so it'll press fit over the D44 tubes:




Then moved the whole thing around in the shop and set the drivetrain into the frame:



Joe
 
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BlackBII

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It's so nice to build your own frame and put everything where you want it. Looking good man.

Do you have room to remove that oil filter? Looks really close to the frame rail.
 

RJLougee

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Do you have room to remove that oil filter? Looks really close to the frame rail.
It looks closer than it actually is and I had assumed it would fit. Of course, assumption is the mother of all screw-ups, so based on your question I went and pulled it. No issues, whew!

Next order of business is to find the headers that fit...
Joe
 
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BlackBII

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It looks closer than it actually is and I had assumed it would fit. Of course, assumption is the mother of all screw-ups, so based on your question I went and pulled it. No issues, whew!
Joe
:icon_thumby:

For your front fenders, I bet some Jeep style fender flares would work. Not sure if they would be long enough :dunno:

 

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Sweet! I'll definitely be tuning into this build. So the front is a dana 44 but you're putting 60 outers on it? For headers on my 351w swap I used hedman 88400, they are pretty tight and worked out good for me.

Also, what is your full on buggy? Did you just have a 4 speed atlas and true hi 9 3rd lying around?

I am on 37s with a 117'' wheel base, worked great at Moab and handles very well.
 

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RJLougee

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So the front is a dana 44 but you're putting 60 outers on it?
Correct. High pinion (aka Reverse Cut) D44 center section and tubes, with a 35 spline ARB and 4.88 gears, with 35 spline shafts and D60 outers. Pretty close to D60 strength with @1.5" better ground clearance and 100# less weight. Costs not much less than a D60 to build though...

It will go nicely with the full float 35 spline 9" rear. Still have to build that. Got the Ruffstuff D60 FF axle flange to weld on the 9" housing, I have D50/60 spindles/hubs/rotors already. Ordered up the axle shortening tool kit and this will be first (case of beer..) time shortening a rear axle like this.

For headers on my 351w swap I used Hedman 88400
I do have a set of those in the shop and bolted them on this morning. They do fit, although I'd prefer a long tube for the extra torque... We'll see.

Also, what is your full on buggy?
I posted on your Pirate thread a couple weeks ago when I started, asked if you made the climb out of the Devils Highway Hot Tub on Hells Revenge. My buggy is a tube chassis rig I built in 2011/2. Early Bronco skins, Explorer 5.0, A9P EEC, Wide ratio C-6, Broader manual/reverse valve body, Atlas 4 speed, D60/35 spline inner/outer, True Hi-9 with 35 spline, etc...

https://www.youtube.com/watch?v=Be18CBAxB0Q

Did you just have a 4 speed atlas and true hi 9 3rd lying around?
Had the Atlas sitting there waiting for the next build. A buddy was going out of business and I bought it before he was totally out and got a great deal. Had to order the Hi-9, it'll be here Friday.

I am on 37s with a 117'' wheel base, worked great at Moab and handles very well.
Thanks for the feedback. Still working through those choices...
Joe
 

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vote for hybrid exo

personally, like to see ya build custom jeep style tube fenders out front. still have not done this for my truck but it seems the best way to go for a streetable rig that will take an ass whoopin.. really ties in with the hybrid exo.


been looking at hydro formed custom rails on and off for many years now, it is the best way to go as well imo. especially with out of the norm powertrain selections that i been using.

lots of time nd work....worktime worktime worktime....and tooo much money,

but damn it will be killer.
 

RJLougee

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vote for hybrid exo
I'm 95% sure this is the way I'm going, time will tell. Like so many other questions, exactly how.....

Initially, I'm leaning toward Exo:
1. Single/double halo over the C/B pillars,
2. Front end 1.25" following body lines, and as needed...

Interior:
1. 1.5" for the A/B pillars, some 1.25" for seat mounts.
2. Ties into the under-hood parts and radiator mount.

Personally, like to see ya build custom jeep style tube fenders out front.

This is an idea I can explore. Talk to me about what you're thinking??

But damn it will be killer.
That my friend, is the point.
Joe
 

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Correct. High pinion (aka Reverse Cut) D44 center section and tubes, with a 35 spline ARB and 4.88 gears, with 35 spline shafts and D60 outers. Pretty close to D60 strength with @1.5" better ground clearance and 100# less weight. Costs not much less than a D60 to build though...

It will go nicely with the full float 35 spline 9" rear. Still have to build that. Got the Ruffstuff D60 FF axle flange to weld on the 9" housing, I have D50/60 spindles/hubs/rotors already. Ordered up the axle shortening tool kit and this will be first (case of beer..) time shortening a rear axle like this.



I do have a set of those in the shop and bolted them on this morning. They do fit, although I'd prefer a long tube for the extra torque... We'll see.



I posted on your Pirate thread a couple weeks ago when I started, asked if you made the climb out of the Devils Highway Hot Tub on Hells Revenge. My buggy is a tube chassis rig I built in 2011/2. Early Bronco skins, Explorer 5.0, A9P EEC, Wide ratio C-6, Broader manual/reverse valve body, Atlas 4 speed, D60/35 spline inner/outer, True Hi-9 with 35 spline, etc...

https://www.youtube.com/watch?v=Be18CBAxB0Q



Had the Atlas sitting there waiting for the next build. A buddy was going out of business and I bought it before he was totally out and got a great deal. Had to order the Hi-9, it'll be here Friday.



Thanks for the feedback. Still working through those choices...
Joe
I knew I was getting De ja vu reading this thread, I knew I saw it somewhere else already lol. I'm definitely curious to see how your front axle comes together and holds up. I keep getting told myy 44 with chromos is too small of an axle, but it's still kicking! I don't really see much advantage in a 60 since I don't really plan to ever go bigger than 40, I get around great on 37s.

Dude you made devils hot tub look too easy! Im looking forward to this build a lot!
 

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Love the video. I would like to go wheeling out west some day.

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