89/91 Ranger TDI Build

[maddyn]

So Figured it was probably time to start a build thread for my truck. I am a long time lurker on the Ranger Station, mainly for the wealth of knowledge that it is.

I used to own a '92 Extra Cab 4.0 on 35's with a Duff Lift that I wheeled quite a bit, but finally sold back in 2020 because I didn't drive it much. However I found my life just wasn't complete without a Ranger, so last year I started working on a project.

The plan is to take this '89 Regular Cab, Short Box 4x4 frame, and drop a 91' Extra Cab body on it. Swap in a 2.0l TDI motor, and have fun wheeling and daily driving it

I spent the last year stripping down the Regular cab to the frame, and sand blasting the frame

Also spent a little time on the underside of the Extra Cab with some paint and Raptor Liner while I had equipment around to lift things up

Just last weekend finally got around to patching a few spots on the frame before I get some paint on it

Have also been working on building some lift brackets for the front axle. I tried to model them after the STX lift brackets, except with 2" of lift. Need to get a press brake to bend things up still. Plan is to run this, with a cut and turn at the ball joints for the total lift

Hoping to at least be able to get this thing on it's own axles with a cab on the frame this year, but we'll see how things go. I also found an 04' Passat with the BHW 2.0l TDI that I need to pull out and start cleaning up and getting ready for the swap. I will try and keep things updated here, I am horrible about stopping to take pictures of things.

 

[Blmpkn]

Sweet, gonna have another stubby around. You gonna cut the factory bed down or fab up your own?

 

[maddyn]

Planning on fabing up a flat bed for it. The plans are to have something that I can wheel, maybe do some overlanding/camping in and just have fun with

 

[Blmpkn]

Looks good so far! Welcome and good luck and have fun with the rest of it

 

[bobbywalter]

you should just be a good chap and mail me that cab.....


solid.



kewlz to see another diesel in the workz

 

[maddyn]

Hah, yeah I'll have some stuff to get rid of for sure. I do have a short bed from the 91 that is solid, just has a crappy paint job on it from someone painting black over factory red. Short bed from the 89 has some rust in the wheel arches and a few dents.

Weather was nice enough yesterday to get the frame painted. Got one coat of por15 on it. Probably need to get another coat, and then top coat it

Does anyone happen to know the weight of an empty extra cab body? We moved stuff around with the excavator, but I'd like to get this in my carport on a level surface to set the body on, plus I have to fab a rear body mount perch. so it would be nice to have it sitting level to figure things out.

 

[maddyn]

Well not a ton of work done for a while, lot of research and planning, little bit of clean up on parts, and figuring out what things I need to purchase

Got the TDI pulled out of the donor car

Been doing a lot of planning for plumbing and routing and where things need to be for this motor. It does look like I can retain the BHW A/C pump on the passenger side of the motor, and then use a BRM accessory bracket for the other side of the motor so I can install another A/C pump and convert it to an air compressor for on board air. Just have to find a used compressor for that side and get the belt pulleys all figured out.


I did get the frame set on another trailer frame I have and got it all leveled up so I can get the cab mounting figured out. Just need a solid weekend to get things fabbed up and mounted

Got the steering knuckles for the D35 sand blasted and painted. Tried out some Steelit paint, looks great hopefully it will hold up to wear and tear. I did get the axle broke down, all joints pulled out, and just getting a list of parts to get it back together

Still looking for a rear axle, would like to find a disk 8.8", if anyone knows of an exploder parked in a backyard in the PNW, that would be great. The list of things at this point is to get the cab mounted so I can get it sitting at home and be able to work on things as I get a little time. Get front axle brackets welded up and axle mounted so I can figure out how much I need to cut and turn. And then just keep on with the project

 

[maddyn]

Got a fair amount of time spent on the project this weekend, along with some nice weather.

Body is sitting on the frame now and got the rear body mounts fabbed up. If anyone is curious, an extra cab on a regular cab frame puts the rear body mounts about dead center of the front leaf spring hanger.

Truck looks great, just has some redneck spacers under the front right now to figure height, but I got bolts ordered and just need to fab up some body lift blocks and get everything bolted down