My 99 Ranger Build Thread

[RJLougee]

On the back, I wanted to make sure that "if" I had a catastrophic failure that the rear axle/link mount wouldn't come through the bottom of the fuel cell, etc... mounted back there. So a nice welded in cross0bar. 1.25" .25" wall tube. Should keep stuff apart... Also mocking up the brake lines...

I also dropped the bottom of the fuel cell mount and added an 11 gauge flat panel to mount the fuel cell, as well as boxes, etc... that end up back there.

That's all for tonight, more tomorrow...
Joe

 

[RJLougee]

Finished all of the rear axle stuff, lower shock mounts welded pn, painted, all the brake lines run and tightened up, etc...

To recap: Ford 9" with Ruffstuff full-floater ends, D60 hubs with Chevy 3/4 ton rotors and Lugnut4x4 caliper brackets for the Ford spindles. Nice setup. True Hi-9 center section, 4.88 gears and 35 spline spool, dual load bolts, 1310 pinion. Added the big El Dorado rear calipers, with E-brake provision, sourced complete from Ruffstuff. I am a little worried about how the rear e-brake cable bracket looks pretty bent up?? It for sure is closer to the caliper body than a set of stock Chevy parts look. Once my cables get here, we'll see how it fits together. Coated stainless brake hoses complete the rear brakes. Just waiting for another 10" hose to tie the front/back together and this will be ready for fluids...

And the Yukon lock-outs are just plain sexy...

 

[RJLougee]

Once the axle was done I could get the rear plate in. The tank will be bolted directly to it and there will be a couple of mounts welded on underneath to bolt the retainers to as well. Then I'll have to figure out exactly how to mount the rest of the plate near the end/rear.

 

[RJLougee]

Generally, I plan to mount the plate with some Rivnuts.. A couple ideas, either bend over some material and bolt through it on the side of the frame, into the Rivnuts, or bolt through the top of the plate, into Rivnuts, but with countersunk holes and the correct machine screws. Here is a shot of the practice Rivnut in the same material, just to see how it looks/works...

 

[RJLougee]

Took the front end apart and starting getting it all set.

Pulled the tie-rods, finished welding the tube adapters to the tube all the way around, then painted them up. Also had to ream out the hole through the Pitman arm to accept the tie-rod from the top.

Rebuilt the lower shock mounts. I added some triangular bracing under the mounts and got the tabs welded on nicely. Then Pulled the hub/rotor assy, repacked the wheel bearings with grease and installed new rotors. Then painted it all up. Finished installing matching brake hoses, still need to install the hard line from left/right, as well as the breather hose and the ARB air line. I'll be running a similar coated braided stainless line from Independent4X4.

To recap,high pinion D44 from a '77 F250 with 4.88 gears, 35 spline ARB, 35 spline D60 inner/30 spline outer shafts, D60 hub/Rotor and '92 F350 innner/outer knuckles, stock F350 dual piston calipers. Stock 30 spline Ford lock-outs. I figure I'll plan this as the "fuse".

 

[RJLougee]

Started finishing up the interior, getting the cage welded together, mounted to the floor, crossbars, etc...

Big progress on installing the center "console" and cutting the holes for the shifters, E-brake handle and mocking things up. Waiting on the switch panels to arrive to get that part done.
Joe

 

[bobbywalter]

Interesting setup on the center console.


I don't want to give up that much space.

That and I want to be able to easily remove the tunnel from Inside.

Not sure I will be able to pull that off....in my head it can work. Maybe it's because I have been driving around with a rotted out floor for so many years...

I won't let my grandchildren ride in it anymore it's getting so bad....so I need to do something.....

hurry up I need some ideas.

 

[RJLougee]

I hear you on the rust. I grew up in the NorthEast and it was always such a PIA to get old bolts off, rusted through everything.... So much better here in Colorado....

The console still allows the tunnel cover to be removed/installed. I still have to put mine back and anticipate putting a small rubber boot over it to allow the shifter cables to come through and minimize trail dust.

I have been toying with the idea of installing a PRP Pre-Teen seat in the back/center of this rig so my 11 yo grandson can ride with me and his dad.
Joe

 

[RJLougee]

A question for the masses: Is it relatively easy to convert the '99 Ranger bolt in style of rear windows in the Xtracab to the push out/hinged windows? By "relatively easy" I mean: drill holes and align parts, not "replace the entire window surround". I do not need/care about any of the plastic surrounding parts, they are all gone since I stripped out all of the superfluous wieght I could get rid of. No headliner, door panels, etc... If it's plastic, it's gone. I even took the electric door locks out since I didn't want/need to wire any of it in.

OK, so I spent some quality time with the search button, but I do not see any significant threads.

Help appreciated.
TIA, Joe

 

[sgtsandman]

I think they don't require any modification to your doors since you got rid of the interior plastic.

 

[bobbywalter]

i was just looking at a set again....ran out of time.

on my shitty memory...the ext cab windows just bolt in...aslong as you have the hardware.


theres up 92

93-97 ish

97ish to the end....and i think 2 styles in there somehow....but they are interchangeable.

 

[RJLougee]

Thank you Gents, looking at the holes and what is there, it looks pretty obvious that there is already the cut-outs for mounting the flip out handle, etc... I'm planning a trip to the 'Yard this weekend, we'll see how it turns out.

On a totally unrelated note.... been kinda bummed this week since the Moab Bronco Safari should be going on and I'm stuck here... It is truly one of my favorite events. Maybe I can make it to a TRS event this year, something to look forward to!
Joe

 

[RJLougee]

So as I'm working on the interior, "console", wiring, etc... I've been generally going off this template I made up.

And so far, so good:

 

[RJLougee]

I also got the universal e-brake cable set and got everything hooked up:

Unfortunately, it worked so well that when I pulled up on the handle, it went three clicks and blew the ball off the end of the passenger side cable end...... No bueno...

So now I'll need to add some slack to the system and replace the inner cable on that side.
Joe

 

[bobbywalter]

shit like that makes you want to punch puppies.