My 99 Ranger Build Thread

[RJLougee]

So after all that work, I needed a break. I went up to my cabin by 11 Mile reservoir and spent a couple days relaxing. One afternoon I was sitting on the porch reading and looked up to find these browsing across the ridgeline below the cabin. Looked like a bachelor herd of about 12. Not the greatest pics, they were 4-500 yds away and I'm trying to focus the camera through my binos to get decent pics....

 

[RJLougee]

And back to the grindstone.....

The last couple days have been getting everything finalized to start the rig and today it finally happened. Set all of the electrical up on the passenger seat, just put together so it will work, "proof of concept" as it were...

Once I got the base info/tune loaded into TunerStudio, it fired right up on the first crank. A couple things were not correct, right off the bat. 1: the hydraulic ram is backwards in relation to how it needs to be plumbed. I did it iaw the instruction; however, it needs the flow reversed to work the same as the steering box. 2: The EGR plug/bolt adapter in the front of the driver head wasn't in there, so exhaust gas was pushing out the front head area. Had to pull the PS/AC bracket out, drill out the hole in the bracket and run a bolt in there. Once I did that, it was just the "normal" loud of a 408 stroker with forged internals in small garage and bouncing off the concrete floor.... 3: I am probably going to have to pull the hydroboost off the firewall and invert it to get it to bleed correctly and build pressure. I've done it before on a similar build, never had any issues once put back together, just didn't want to bleed correctly with the accumulator on the high side.

And a screenshot of TunerStudio MS as I monitor what's going on and looking at making changes to the base programming... Still have to trim fuel and a few other things, but it's a very good start.
Joe

 

[Kirby N.]

Sweet build. We are almost neighbors.

 

[RJLougee]

Sweet build. We are almost neighbors.

Yes, I commented on your build a while back, sweet looking rig!
Joe

 

[RJLougee]

So not a huge update, but this is the time that little changes take forever to actually build and implement.

Got the dash all built. On the passenger side the part with the small cut-out (the Crane Ignition heat sink sits there, figured a little airflow couldn't hurt...) will actually drop down and allow access to all of the components I want hidden/protected from the average big-footed booby that often cohabits my passenger seat.... If he can't kick it, he can't hurt it????

The gauge to the left of the steering column cut-out is the Transmission Temp. Still waiting on a part to get the wiring/sender installed.

Next up, the new steering column...
Joe

 

[Curious Hound]

That's looking very nice.

 

[RJLougee]

Man, I'm looking at this page and realize there is a lot of stuff I did not document/upload over the last week or so. OK, I'll get to that in the next couple days....

I spent much of the last week working on the brake systems. Meaning... I had no brakes. I swapped out several different hydroboost systems, made brackets, adapters, bled systems, etc... One worked "kinda", one was locked in the middle and wouldn't move, etc... None did what they were supposed to.

So.... I ordered a new/rebuilt hydroboost unit from an Astro van. Of course, once I got it in my hands, I realized the current master cylinder was not going to work correctly with it.... So, some research and I got a nice MC from an early 70s Corvette.

So put everything on and get it bled, lined up, etc... and it still didn't want to work. After some troubleshooting, looked like the hydroboost plunger was not out far enough, so there was not enough pre-load on the MC. Swapped out the rod, put back together and now I HAVE BRAKES!!!!

If you're wondering what the clear/braided hose is, it's the air intake for the OBA compressor so it can draw clean/lubricated air from inside the passenger compartment. The filter is next to the roll cage/dash corner near my seat.
Joe

 

[RJLougee]

And today, for the first time since I tore everything apart and started this build, I drove the Ranger!!! Not much, but pulled it out of the shop, took a tour of the back yard and then drove back over to the front apron on the shop. Still lots to do, but it runs and drives, so it's all little stuff from here.

WOO HOO!!
Joe

 

[RJLougee]

So, the first thing I didn't talk about is the steering column. I didn't like the previous versions with the 3/4" rod passing through a couple of heim joints, so I replaced that with some bronze oilite bushings in some DOM tubing. I didn't really like that some much either, so this is what I ended up with.

Some 1.75", .188 wall DOM, with a pair of XiKe Flanged Ball Bearings ID 3/4" x OD 1-3/8", one at each end. The bearings are pretty tight going into the tubing and the rod was also pretty tight going through. NO WOBBLE with those parts. I welded a 6"x5" plate to the lower bar and used a pair of 'U' bolts to bolt the tubing down. So far, so good. If I need to I'll add a support at the firewall.

Most of the wiring is in and connected to the switches that will power them, with the switch panels mounted. Overall electrical cut-off switch is active and working.

 

[RJLougee]

Got a few things done. Drilled the holes and put the Rivnuts in the rear bumper for the rear lights. Bolted doen nicely...

 

[RJLougee]

Once I got it moving, then it was time to start testing stuff. One thing I noticed is that when I hit the switch for the OBA compressor, I could hear the electromagnet powering up, could see it was rotating and should be compressing air, but nothing was showing on the gauge. Some troubleshooting and come to find out, it could not build pressure over about 15 PSI.

So I pulled this compressor off the shelf, got it installed and hit the switch. Took about 7 seconds to run up to 100# and shut off, just like to should!!

 

[RJLougee]

And for today, I got the rear bar cut/welded in for the shoulder straps of the 4-points to mount. Mounted up the belts as well.

Some PRP Daily Driver seats with PRP 4.2 belt system.

Other little tings include running the rear light wiring into some loom and getting it out of the way. As well as getting the fuel cell bolted down.
Joe

 

[RJLougee]

And last, but not least. I built a bracket to hold the PS reservoir in place. A small plate bolts in over the hood hinge and is triangulated to the top of the shock tower. The reservoir itself is held in place with a QuickFist Superclamp mount. I use the same system on my buggy, been working great for years, figure this will do...
Joe

 

[Blmpkn]

Awesome. That thing is gonna be a blast.

 

[Curious Hound]

Those seats look nice.