Devorak
Active Member
- Joined
- Jun 30, 2011
- Messages
- 41
- Reaction score
- 1
- Age
- 40
- Location
- North Shore
- Vehicle Year
- 1991
- Make / Model
- Ford
- Engine Size
- 4L
- Transmission
- Manual
Ive had my truck for a few years meow, and have taken it out on camping/ wheeling trips a couple dozen times. I plan on making an expedition trail rig that can go where I want and not have to worry about breaking anything. This will be a slow paced build up I'm thinking, because funds are tight I want to do it right the first time.
FUTURE PLANS
-exocage with built in roof top storage that folds open for a roof top tent
-narrowed front dana 60 and rear 10.25
-lockers front and rear
-maybe 5.13 or lower gearing
-onboard air
I just found off craigslist a 2002 hp dana 60 from an f350. been stored since 2003 in a garage. complete minus gears for $240
I need to find an appropriate rear end or Ill have to run a wheel stud conversion so I have the same wheels all around.
Ive started the narrowing on the 60 and it sits at 62" WMS-WMS. I want minimum 37's and Ideally 40's with lots of body trimming and not too much stick out past the fender flares.
here's some pics of the day I bought it, bumper build, 4 runner seats, axle narrowing and what ever else I can find in my computer, lol.
I would love lots of feedback and criticism on what im doing wrong or right so I don't build myself into a corner, so to speak. My building background as far as trucks goes is green, but I am a certified welder since 2007 with basically 4 years of fabrication experience in the R&D field of machinery. I know how to build it strong and I have some good common sense going on in my brain,
View attachment 7768
View attachment 7769
these two are of the day I brought it home. those are 34's with roughly 70% left
View attachment 7758
Used factory bolt holes with 3/4" by 4" flat bar for a tow point. winch plate is 1/2" plate. mounting bracket is laced through and welded both sides.
View attachment 7759
View attachment 7766
View attachment 7767
View attachment 7760
View attachment 7761
re-used the bull bar that came with the truck. I like the look of it
View attachment 7762
This is the rear bumper that came with it. I cut off the weak side extension and the tow points. The tow points were only welded to the face of the bumper and no where near inline with the frame.
View attachment 7763
old one vs. mine. I laced mine through the bumper, welded both sides and welded it to the bumper bracket that gets bolted to the frame. much better.
View attachment 7764
View attachment 7765
I also made some slots for some fogs lights that I re-purposed into reverse lights. wired in a relay and used the power wire for the stock reverse lights as the switching wire for the new relay. basically when I put it in reverse the relay closes and power goes down the newly run line to the new lights.
View attachment 7776
got some leather and abused 4runner seats for $60. welded some 1/4' flat bar
highlighted with red arrows to the seat frame. then welded my stock seat frame to the flat bar.
View attachment 7777
meaning everything bolts up stock and is strong and comfy as hell
On to the 60!
View attachment 7770
old jewlery
View attachment 7771
View attachment 7772
no jewlery
View attachment 7773
this is how much im cutting off
View attachment 7774
here it is re-welded
View attachment 7775
I did a root and a two pass cap. due to not having a proper jig to hold it how I want, I had to cap it in 3 sections. though the welds are strong they are ugly to me. I have a few peaks and valleys going on that im not thrilled about, but not overly concerned with.
FUTURE PLANS
-exocage with built in roof top storage that folds open for a roof top tent
-narrowed front dana 60 and rear 10.25
-lockers front and rear
-maybe 5.13 or lower gearing
-onboard air
I just found off craigslist a 2002 hp dana 60 from an f350. been stored since 2003 in a garage. complete minus gears for $240
I need to find an appropriate rear end or Ill have to run a wheel stud conversion so I have the same wheels all around.
Ive started the narrowing on the 60 and it sits at 62" WMS-WMS. I want minimum 37's and Ideally 40's with lots of body trimming and not too much stick out past the fender flares.
here's some pics of the day I bought it, bumper build, 4 runner seats, axle narrowing and what ever else I can find in my computer, lol.
I would love lots of feedback and criticism on what im doing wrong or right so I don't build myself into a corner, so to speak. My building background as far as trucks goes is green, but I am a certified welder since 2007 with basically 4 years of fabrication experience in the R&D field of machinery. I know how to build it strong and I have some good common sense going on in my brain,
View attachment 7768
View attachment 7769
these two are of the day I brought it home. those are 34's with roughly 70% left
View attachment 7758
Used factory bolt holes with 3/4" by 4" flat bar for a tow point. winch plate is 1/2" plate. mounting bracket is laced through and welded both sides.
View attachment 7759
View attachment 7766
View attachment 7767
View attachment 7760
View attachment 7761
re-used the bull bar that came with the truck. I like the look of it
View attachment 7762
This is the rear bumper that came with it. I cut off the weak side extension and the tow points. The tow points were only welded to the face of the bumper and no where near inline with the frame.
View attachment 7763
old one vs. mine. I laced mine through the bumper, welded both sides and welded it to the bumper bracket that gets bolted to the frame. much better.
View attachment 7764
View attachment 7765
I also made some slots for some fogs lights that I re-purposed into reverse lights. wired in a relay and used the power wire for the stock reverse lights as the switching wire for the new relay. basically when I put it in reverse the relay closes and power goes down the newly run line to the new lights.
View attachment 7776
got some leather and abused 4runner seats for $60. welded some 1/4' flat bar
highlighted with red arrows to the seat frame. then welded my stock seat frame to the flat bar.
View attachment 7777
meaning everything bolts up stock and is strong and comfy as hell
On to the 60!
View attachment 7770
old jewlery
View attachment 7771
View attachment 7772
no jewlery
View attachment 7773
this is how much im cutting off
View attachment 7774
here it is re-welded
View attachment 7775
I did a root and a two pass cap. due to not having a proper jig to hold it how I want, I had to cap it in 3 sections. though the welds are strong they are ugly to me. I have a few peaks and valleys going on that im not thrilled about, but not overly concerned with.